VP-18-101-All-p-001 g.t. Mechanical Running Test Procedure Ms5002c

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CLIENTE - CUSTOMER DAELIM x KNPC

FIRENZE LOCALITA' - PLANT LOCATION KUWAIT

COMMESSA - JOB 1800055 58

IMPIANTO - PLAN FOURTH GAS TRAIN PROJECT (LPG4)

TITOLO - TITLE

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1 Rev. Sh. 8; 12; 17; 18; 19; 20 A.V. 02/05/11 SOM 6676761 / 4

0 EMESSO - ISSUED A.V. V.S. S.M. 01/03/11 LINGUA-LANG. PAGINA-SHEET REV

DESCRIZIONE - DESCRIPTION PREP'D CONT-CHK'D APP-APPR'D DATA - DATE A 1 / 2 Il presente documento di propriet NUOVO PIGNONE. A termine di legge ogni diritto riservato. SOSTITUISCE IL - REPLACES

This document is the property of NUOVO PIGNONE. All rights are reserved according to law. SOSTITUITO DA - REPLACED BY

G.T. MECHANICAL RUNNING TEST PROCEDURE

MS5002C

20100622VP-18-101-ALL-P-001

20100622

20100622

20100622 Pls, change the document no.

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SOM 6676761 / 4

LINGUA-LANG. PAGINA-SHEET

REV DESCRIZIONE - DESCRIPTION A 2 /3 Il presente documento di propriet NUOVO PIGNONE. A termine di legge ogni diritto

riservato. SOSTITUISCE IL REPLACES This document is the property of NUOVO PIGNONE. All rights are reserved according to law. SOSTITUITO DA - REPLACED BY

CONTENTS 1. GENERAL

2. MACHINE ARRANGEMENT 2.1. Job items 2.2. Test Room items

3. CHECKS PERFORMED PRIOR TO TESTING

4. TEST PROGRAM

4.1. No-load mechanical test with low pressure rotor locked 4.1.1. Auxiliary system (note) 4.1.2. Start-up of machine 4.1.3. Operating at maximum continuous speed

4.1.4. HP rotor overspeed trip. 4.1.5. Reading of no-contact probes 4.1.6. Reading of bearing metal temperature

4.2. No-load mechanical test with low pressure rotor free 4.2.1. Start-up and running at maximum continuous speed

4.2.2. LP rotor overspeed trip. 4.2.3. Reading of no-contact probes 4.2.4. Reading of bearing metal temperature

4.3. Measurement of vibration 4.3.1. Acceptance criteria for vibrations level

4.4. Measurement of bearings oil discharge temperature 4.4.1. Acceptance criteria for bearings oil discharge temperature

4.4.2. Inspection after test

5. SPARE ROTOR MECHANICAL TEST (Only for N.P. job 1800056)

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ANNEXES

A. Test sequence Diagram.

B. No-load mechanical test results with low pressure rotor locked.

C. No-load mechanical test results with low pressure rotor free.

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1. GENERAL

The purpose of this procedure is that of describing the main procedures carried out in testing the MS5002C two-shaft gas turbine. The test is performed to verify mechanical operation. For this purpose, analysis of parameters regards measuring pressures and temperatures of the lube oil system and checking vibrations as well as all other checks required to verify the correct operation of the machine.

2. MACHINE ARRANGEMENT

The setup for no-load mechanical test of the turbine is specified below.

2.1. Job items

- Engine lube oil piping and sealing air systems piping. - Engine fuel system piping. - Antisurge valves. - Flame detectors. - Igniter plugs.

- Machine instrumentation. - Burners.

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2.2. Test Room Items

- The turbine control panel. - The power supply board for the electric motors (Motor Control Center). - The exhaust and intake ducts. - Auxiliary baseplate with auxiliary gear-box, lube oil system, lube oil emergency system, hydraulic oil system supply, control oil system and fuel gas valves. - Starting system. - Oil cooling system. - Ventilation system. - Gas detection system.

Note:

Lube oil flow to the turbine will be measured by shop flow meter. The turbine will be fuelled by natural gas from the national network. Interruption of test running due to test facilities fault will require only N.P. investigation and correction, official test prosecution will take place as soon as fault will be solved. No note of that will be added on test report.

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3. CHECKS PERFORMED PRIOR TO TEST

Checks are carried out on the electric and pneumatic connections according to API616 para 6.3.3.1.3., on the calibration of the instrumentation. Checks prior to test will be done before the internal test and not repeated during the official test. The Shop control system protects the gas turbine and all auxiliary systems.

4. TEST PROGRAM

Testing department will reserve the right to decide to start the test with the low pressure rotor locked or free at its convenience.

4.1. No-load mechanical test with low pressure rotor locked

4.1.1. Auxiliary system (note)

The shop auxiliary systems supply the gas turbine, control the lubrification system, the high-pressure oil and the control oil (if required) at the required pressures. The oil Type use for the test is ISO VG32.

4.1.2. Start-up of machine

All the oil systems are controlled by shop system. The start is given from the control panel, and the starting motor is switched

on.

At about 20% of rated speed of the turbine purge, ignition and warm up will be made and then begins the acceleration sequence.

During the acceleration stage, at approximately 60% of rated speed the starting motor is switched off, at approximately 85-95% of rated speed, the antisurge valves close. Small leakage from casing flanges during the test will be considered acceptable.

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4.1.3. Operating at maximum continuous speed

At 100% of speed (5100 rpm, max. cont. speed) and IGV at 56 deg with oil temperature and pressure on the bearings header at the required values, measurements are made each 30 minutes for a period of 4 hours (as described in Annex A).

4.1.4. HP rotor overspeed trip(@ 110% of rated control speed)

Model MS5002C HP rotor is equipped only with shop electronic safety device. It is sufficient to verify only one trip for the sole purpose of verifying the mechanical behaviour of the rotor. The overspeed control is performed by control system, during the test the shop control panel will be used.

4.1.5. Reading of no-contact probes (Annex B)

The machine is equipped with no-contact probes for vibration and axial displacement, the readings will be acquired during the mechanical test using shop monitors.

The no-contact vibrations readings are merely indicative.

4.1.6. Reading of bearing metal temperature (Annex B)

The machine is equipped with thermoelements in the bearing metal, the readings will be acquired, during the mechanical test, using shop temperature reading device.

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SOM 6676761 / 4 1 Revised sheet LINGUA-LANG. PAGINA-SHEET

REV DESCRIZIONE - DESCRIPTION A 8 /9

Il presente documento di propriet NUOVO PIGNONE. A termine di legge ogni diritto


4.2. No-load mechanical test with low pressure rotor free

Release the low pressure rotor.

4.2.1. Start-up and running at maximum continuous speed

Start the turbine and run it up to 105% of speed of the low pressure shaft (4900 rpm) with oil temperature and pressure on the bearings header at the required values, measurements are taken every 30 minutes for a period of 4 hours (as described in Annex B). The test is performed with an idling adapter that simulates the effect of the power coupling.

4.2.2. LP rotor overspeed trip (@ 110% of rated control speed)

Model MS5002C LP rotor is equipped only with shop electronic safety device. It is sufficient to verify only one trip for the sole purpose of verifying the mechanical behaviour of the rotor. The overspeed control is performed by control system, during the test the shop control panel will be used.

4.2.3. Reading of no-contact probes (Annex C)

The machine is equipped with no-contact probes for vibration and axial displacement, the readings will be acquired during the mechanical test using shop monitors.

The no-contact vibrations readings are merely indicative.

4.2.4. Reading of bearing metal temperature (Annex C)

The machine is equipped with thermoelements in the bearing metal, the readings will be acquired, during the mechanical test, using shop temperature reading device.

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4.3. Measurement of vibrations

For measurement of vibrations during the test job velocimeters are used specifically:

- 2 job velocimeters on the Nr. 1 bearing support in vertical position - 2 job velocimeters on the Nr. 4 bearing support in vertical position

4.3.1. Acceptance criteria for vibrations level

The acceptance criteria for the vibrations during the test is based on the values read on the job velocimeters.

The vibrations, not filtered and measured with the job velocimeters, shall not exceed the limit of 6.35 mm/s (0-peak) as a total, at maximum continuous speed, after the turbine thermal stabilization has reached.

During speed and/or thermal transients, the maximum acceptable level of vibration is 12.7 mm/s (0-peak) as a total.

No analysis is made of the critical speeds during the test, since the turbine is a standard production one with known dynamic response and well-tested mechanical functioning.

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4.4. Measurement of bearings oil discharge temperatures

The inlet oil temperature to the bearings (LT-TH) and the oil discharge temperature from each journal bearing (LT-B1,2,3,4,D) and from the thrust bearing of the high pressure shaft (LT-BT1D) will be acquired by shop system.

4.4.1. Acceptance criteria for bearings oil discharge temperature for Model MS5002C

The required inlet temperature (LT-TH) is between 50C 55C.

MAXIMUM ACCEPTANCE INCREASE VALUES WITH LOW PRESSURE ROTOR LOCKED AT MAX. CONTINUOUS SPEED OF HIGH PRESSURE SHAFT (100%).

(LT-B1D) (Nr. 1 bearing) T 15 C (LT-B2D) (Nr. 2 bearing) T 37 C (LT-BT1D) (Nr. 1 thrust brg.) T 15 C

MAXIMUM ACCEPTANCE INCREASE VALUES WITH LOW PRESSURE ROTOR FREE AND AT MAX. CONTINUOUS SPEED (105%)

(LT-B1D) (Nr. 1 bearing) T 12 C (LT-B2D) (Nr. 2 bearing) T 25 C (LT-B3D) (Nr. 3 bearing) T 17 C (LT-B4D) (Nr. 4 bearing) T 12 C (LT-BT1D) (Nr. 1 thrust brg.) T 13 C

Bearings white metal temperature shall not exceed 105C.

4.4.2. Inspection after test

No bearing inspection is provided for after completion of mechanical test.

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REV DESCRIZIONE - DESCRIPTION A 11 / 12



5. SPARE ROTOR MECHANICAL TEST (Only for N.P. job 1800056)

The test on high pressure and low pressure spare rotors is carried out prior to that on the main rotors. These tests will be performed using the same procedures as that of mechanical test on the main rotor described in the preceding paragraphs.

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ANNEX A

Speed Speed

Time Time

5140

0 0

5100

110%

105%100%

LP ROTOR HP ROTOR

4h

4900

110%5610

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ANNEX B

MEASUREMENTS MADE DURING TEST

Customer: DAELIM X KNPC

N.P. Job Order: 1800055; 1800056; 1800057; 1800058

Turbine: N.P. Serial Nr.:

HP rotor Serial Nr.:

LP rotor Serial NR.:

Schematic piping diagram and device summary: SOM5081819; SOM5081820

Data measured with H.P. rotor at maximun continuous speed (100%) (5100 RPM) (4.1.3)

VIBRATIONS (4.3)

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Machine Trasducer Nr. 1 V (total 0-Pk) 39V1A 231 VE 5061A mm/s Machine Trasducer Nr. 1 V (total 0-Pk) 39V1B 231 VE 5061B mm/s

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Machine Trasducer Nr. 1 V (total 0-Pk) 39V1A 231 VE 5061A mm/s Machine Trasducer Nr. 1 V (total 0-Pk) 39V1B 231 VE 5061B mm/s

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ANNEX B

Data measured with H.P. rotor at maximun continuous speed (100%) (5100 RPM)

OIL PRESSURE

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Bearings Header (*) LP-TH

barg Control Oil System (*) LP-TBH

barg Hydraulic Oil System (*) LP-HP

barg Oil flow to engine (*) Q1

l/min

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Bearings Header (*) LP-TH

barg Control Oil System (*) LP-TBH barg Hydraulic Oil System (*) LP-HP barg Oil flow to engine (*) Q1 l/min

(*) Note: Shop items only for reference.

TEMPERATURE (4.4.1.)

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Bearing Header LT-TH 231 TE 5159 C Nr. 1 Bearing LT-B1D 231 TE 5098 C Nr. 2 Bearing LT-B2D 231 TE 5099 C Thrust Bearing LT-BT1D 231 TE 5097 C Mean Turbine Exhaust Temperature TT-XDM

C

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Bearing Header LT-TH 231 TE 5159 C Nr. 1 Bearing LT-B1D 231 TE 5098 C Nr. 2 Bearing LT-B2D 231 TE 5099 C Thrust Bearing LT-BT1D 231 TE 5097 C Mean Turbine Exhaust Temperature TT-XDM C

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ANNEX B


READINGS OF NO-CONTACT PROBES (4.1.5.) (Not filtered, peak-to-peak)

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Bearing 1 Vertical XE-1X 231 XE 5063X um Bearing 1 Horizontal XE-1Y 231 XE 5063Y um Bearing 2 Vertical XE-2X 231 XE 5064X um Bearing 2 Horizontal XE-2Y 231 XE 5064Y um Bearing 1 Axial Displ. XZ-1 231 ZE 5061A mm Bearing 1 Axial Displ. XZ-2 231 ZE 5061B mm

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Bearing 1 Vertical XE-1X 231 XE 5063X um Bearing 1 Horizontal XE-1Y 231 XE 5063Y um Bearing 2 Vertical XE-2X 231 XE 5064X um Bearing 2 Horizontal XE-2Y 231 XE 5064Y um Bearing 1 Axial Displ. XZ-1 231 ZE 5061A mm Bearing 1 Axial Displ. XZ-2 231 ZE 5061B mm

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ANNEX B


READINGS OF BEARINGS METAL TEMPERATURE

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Journal Bearing 1 Metal Temperature BT-J1-1 231 TE 5063A C Journal Bearing 1 Metal Temperature BT-J1-2 231 TE 5064A C Journal Bearing 2 Metal Temperature BT-J2-1 231 TE 5067A C Journal Bearing 2 Metal Temperature BT-J2-2 231 TE 5068A C Thrust Bearing 1 Metal Temp. Active side BT-TA1-1 231 TE 5061A C Thrust Bearing 1 Metal Temp. Active side BT-TA1-2 231 TE 5066A C Thrust Bearing 1 Metal Temp. Inactive side BT-TI1-1 231 TE 5062A C Thrust Bearing 1 Metal Temp. Inactive side BT-TI1-2 231 TE 5065A C

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Journal Bearing 1 Metal Temperature BT-J1-1 231 TE 5063A C Journal Bearing 1 Metal Temperature BT-J1-2 231 TE 5064A C Journal Bearing 2 Metal Temperature BT-J2-1 231 TE 5067A C Journal Bearing 2 Metal Temperature BT-J2-2 231 TE 5068A C Thrust Bearing 1 Metal Temp. Active side BT-TA1-1 231 TE 5061A C Thrust Bearing 1 Metal Temp. Active side BT-TA1-2 231 TE 5066A C Thrust Bearing 1 Metal Temp. Inactive side BT-TI1-1 231 TE 5062A C Thrust Bearing 1 Metal Temp. Inactive side BT-TI1-2 231 TE 5065A C

CHECKING HP ROTOR OVERSPEED TRIP (4.1.4.)

Electronic overspeed trip set (5610 50 RPM)

Electronic overspeed trip found

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ANNEX C

Data measured with L.P. rotor at maximun continuous speed (105%) (4900 RPM) (4.2.1.)

VIBRATIONS (4.3)

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Machine Trasducer Nr. 1 V (total 0-Pk) 39V1A 231 VE 5061A mm/s Machine Trasducer Nr. 1 V (total 0-Pk) 39V1B 231 VE 5061B mm/s Machine Trasducer Nr. 4 V (total 0-Pk) 39V2A 231 VE 5062A mm/s Machine Trasducer Nr. 4 V (total 0-Pk) 39V2B 231 VE 5062B mm/s

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Machine Trasducer Nr. 1 V (total) 39V1A 231 VE 5061A mm/s Machine Trasducer Nr. 1 V (total) 39V1B 231 VE 5061B mm/s Machine Trasducer Nr. 4 V (total) 39V2A 231 VE 5062A mm/s Machine Trasducer Nr. 4 V (total) 39V2B 231 VE 5062B mm/s

OIL PRESSURE

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Bearings Header (*) LP-TH

barg Control Oil System (*) LP-TBH

barg Hydraulic Oil System (*) LP-HP

barg Oil flow to engine (*) Q1

l/min

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Bearings Header (*) LP-TH

barg Control Oil System (*) LP-TBH barg Hydraulic Oil System (*) LP-HP barg Oil flow to engine (*) Q1 l/min

(*) Note: Shop items only for reference.

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ANNEX C

Data measured with L.P. rotor at maximun continuous speed (105%) (4900 RPM)

TEMPERATURE (4.4.1.)

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Bearing Header LT-TH 231 TE 5159 C Nr. 1 Bearing LT-B1D 231 TE 5098 C Nr. 2 Bearing LT-B2D 231 TE 5099 C Thrust Bearing LT-BT1D 231 TE 5097 C Nr. 3 Bearing LT-B3D 231 TE 5100 C Nr. 4 Bearing LT-B4D 231 TE 5101 C Mean Turbine Exhaust Temperature TT-XDM

C

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Bearing Header LT-TH 231 TE 5159 C Nr. 1 Bearing LT-B1D 231 TE 5098 C Nr. 2 Bearing LT-B2D 231 TE 5099 C Thrust Bearing LT-BT1D 231 TE 5097 C Nr. 3 Bearing LT-B3D 231 TE 5100 C Nr. 4 Bearing LT-B4D 231 TE 5101 C Mean Turbine Exhaust Temperature TT-XDM

C

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ANNEX C


READINGS OF NO-CONTACT PROBES (4.2.3.) (Not filtered, peak-to-peak)

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Bearing 1 Vertical XE-1X 231 XE 5063X um Bearing 1 Horizontal XE-1Y 231 XE 5063Y um Bearing 2 Vertical XE-2X 231 XE 5064X um Bearing 2 Horizontal XE-2Y 231 XE 5064Y um Bearing 1 Axial Displ. XZ-1 231 ZE 5061A mm Bearing 1 Axial Displ. XZ-2 231 ZE 5061B mm Bearing 3 Vertical XE-3X 231 XE 5065X um Bearing 3 Horizontal XE-3Y 231 XE 5065Y um Bearing 4 Vertical XE-4X 231 XE 5066X um Bearing 4 Horizontal XE-4Y 231 XE 5066Y um Bearing 4 Axial Displ. XZ-3 231 ZE 5062A mm Bearing 4 Axial Displ. XZ-4 231 ZE 5062B mm

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Bearing 1 Vertical XE-1X 231 XE 5063X um Bearing 1 Horizontal XE-1Y 231 XE 5063Y um Bearing 2 Vertical XE-2X 231 XE 5064X um Bearing 2 Horizontal XE-2Y 231 XE 5064Y um Bearing 1 Axial Displ. XZ-1 231 ZE 5061A mm Bearing 1 Axial Displ. XZ-2 231 ZE 5061B mm Bearing 3 Vertical XE-3X 231 XE 5065X um Bearing 3 Horizontal XE-3Y 231 XE 5065Y um Bearing 4 Vertical XE-4X 231 XE 5066X um Bearing 4 Horizontal XE-4Y 231 XE 5066Y um Bearing 4 Axial Displ. XZ-3 231 ZE 5062A mm Bearing 4 Axial Displ. XZ-4 231 ZE 5062B mm

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N. SOM 6676761 / 4 1 Revised sheet LINGUA-LANG. PAGINA-SHEET




ANNEX C


READINGS OF BEARINGS METAL TEMPERATURE (4.2.4.)

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 0' 30' 60' 90' 120' Journal Bearing 1 Metal Temperature BT-J1-1 231 TE 5063A C Journal Bearing 1 Metal Temperature BT-J1-2 231 TE 5064A C Thrust Bearing 1 Metal Temp. Active side BT-TA1-1 231 TE 5061A C Thrust Bearing 1 Metal Temp. Active side BT-TA1-2 231 TE 5066A C Thrust Bearing 1 Metal Temp. Inactive side BT-TI1-1 231 TE 5062A C Thrust Bearing 1 Metal Temp. Inactive side BT-TI1-2 231 TE 5065A C Journal Bearing 2 Metal Temperature BT-J2-1 231 TE 5067A C Journal Bearing 2 Metal Temperature BT-J2-2 231 TE 5068A C Journal Bearing 3 Metal Temperature BT-J3-1 231 TE 5069A C Journal Bearing 3 Metal Temperature BT-J3-2 231 TE 5070A C Thrust Bearing 4 Metal Temp. Active side BT-TA4-1 231 TE 5073A C Thrust Bearing 4 Metal Temp. Active side BT-TA4-2 231 TE 5074A C Thrust Bearing 4 Metal Temp. Inactive side BT-TI4-1 231 TE 5072A C Thrust Bearing 4 Metal Temp. Inactive side BT-TI4-2 231 TE 5075A C Journal Bearing 4 Metal Temperature BT-J4-1 231 TE 5071A C Journal Bearing 4 Metal Temperature BT-J4-2 231 TE 5083A C

Readings Time (minutes) Description Tag N.P. Tag cust. U.M. 150' 180' 210' 240' Journal Bearing 1 Metal Temperature BT-J1-1 231 TE 5063A C Journal Bearing 1 Metal Temperature BT-J1-2 231 TE 5064A C Thrust Bearing 1 Metal Temp. Active side BT-TA1-1 231 TE 5061A C Thrust Bearing 1 Metal Temp. Active side BT-TA1-2 231 TE 5066A C Thrust Bearing 1 Metal Temp. Inactive side BT-TI1-1 231 TE 5062A C Thrust Bearing 1 Metal Temp. Inactive side BT-TI1-2 231 TE 5065A C Journal Bearing 2 Metal Temperature BT-J2-1 231 TE 5067A C Journal Bearing 2 Metal Temperature BT-J2-2 231 TE 5068A C Journal Bearing 3 Metal Temperature BT-J3-1 231 TE 5069A C Journal Bearing 3 Metal Temperature BT-J3-2 231 TE 5070A C Thrust Bearing 4 Metal Temp. Active side BT-TA4-1 231 TE 5073A C Thrust Bearing 4 Metal Temp. Active side BT-TA4-2 231 TE 5074A C Thrust Bearing 4 Metal Temp. Inactive side BT-TI4-1 231 TE 5072A C Thrust Bearing 4 Metal Temp. Inactive side BT-TI4-2 231 TE 5075A C Journal Bearing 4 Metal Temperature BT-J4-1 231 TE 5071A C Journal Bearing 4 Metal Temperature BT-J4-2 231 TE 5083A C

CHECKING LP ROTOR OVERSPEED TRIP (4.2.2.)

Electronic overspeed trip set (5140 50 RPM)

Electronic overspeed trip found

Documents

VP-18-101-All-p-001 g.t. Mechanical Running Test Procedure Ms5002c