CLIENT:

FSO PROJECT

I I p
DOCUMENT DESCRIPTION:

OPERATIONAL TEST PROCEDURE

TURBO GENERATORS

OTP

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lnform.Uon on Status:

P Prwllmlnary for Information

1 1m.ma1 Dlsclpllna Checking
C For Comments or Approval
V Valktfor Constn.Jctlon
A Approved (for Conatn.Jctlon)
X "AaBullt"
FECM Far Eat Construction Manager

Q Copyright Single Buoy Moorings InC (2001) I SBNo: IOH1

 REVISION STATUS I SUMMARY OF CHANGES

REVISION REVISED REVISION REASON FOR

CHAPTERS DESCRIPTION REVISION
p Pretiminary for
Information

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 TABLE OF CONTENTS
1. INTRODUCTION ..................................... ..................................... .............. ...................... 4
1.1 OBJECTIVES ............................ ...... ....... ....................... ........................... .......... ... 4
1.2 ABBREVIATIONS ................... .............. ..... .. .................... ............ .... ...................... 4
1.3 SAFETY ........................ ......................... ..... .......................................................... 4
2. SYSTEM DATA ....... .................. ... .................... ......... ............. .......... .... ............................. 5
2.1 SYSTEM DESCRIPTION ..... ....... .... .......................... ............................................ 5
2.2 SYSTEM LIMITS .................... ................. .......... ..... ..................... ................ ...... .... 5
2.3 SYSTEM DOCUMENTAT ION ........... .. ... ... .... ................. ................ ...................... . 5
3. SYSTEM PRE-REQUISITES ......... ........................... .. ....................... ............ .. ......... .. ...... 6
3.1 TEST EQUIPMENT AND SPECIAL TOOLS .... ..................................................... . 7
3.2 VENDOR ASSISTANCE ................. ................. .... ........ ............. .. ... .. ......... ............. 7
3.3 COMMISSIONING SPARES AND CONSUMABLES ............................................. 7
3.4 ASSOCIATED SYSTEMSffEMPORARIES ............................................ ..... .... ...... 7
4. ONSHORE COMMISSIONING PROCEDURE .. .......... ........ .... .......................................... 7
4.1 SCOPE OF WORK AND TEST DESCRIPTION ..... ............................................... 8
4.2 TEST PREPARATION CHECKS ...... ...... ....... ........................... ............................. 8
4.2.1 Electrical ................................. ............. ......... ............................................ . 8
4.2.2 Instruments ...... ........... .................. .............................. ............................... 8
4.2.3 Mechanical ........ ..................... .................... .. ... ......................................... . 8
4.3 FUNCTION TESTS ..... ................ ........................... .. ... .... ................................ ...... 9
4.3.1 Test Procedures ........ ... ..................... .............. .... ................................ ...... 9
4.3.2 Parallel Operation ............ .................. ............ ...................... .... ..... ............. 10
4.4 CERTIFICATION ....................... .................................................. ..................... ..... 10
4.5 POST COMMISSIONING PROTECTION .............................................................. 10
4.5.1 General ... ...... ............ ..................... .... ......... .................. ......... ... .......... ....... 10
4.5.2 Maintenance and Preservation ...... ........................................................... . 11
5. OFFSHORE COMMISSIONING ................ ............ ...................................................... ...... 11

6. TESTING WITNESSED AND ACCEPTED ................................................................. ...... 12

7. APPENDIX ................................... ........... .................... ...................................................... 13

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1. INTRODUCTION
All the activities described in this document shall be implemented strictly in accordance
with the relevant SBM QA and Safety Corporate Policies as per the standard Purchase
Order and Contract requirement. In particular the appropriate Permit to Work system shall
be strictly adhered to.
Prior to the commencement of these commissioning procedures it shall be the
responsibility of the relevant Systems Engineer to confirm that System Pre-requisites in
Section 3 of this document have been completed and signed off.
For detailed definitions of terms used within these procedures refer to SBM Construction
Completions Manual Document ref. No. S017000.

1.1 SCOPE OF WORK & TEST CRITERIA

Demonstrate the functionality and operability of the Turbo Alternators alongside and on
sea trial.

The procedure will cover the following scope

1.2 ABBREVIATIONS
SDV Shutdown Valve
HPU Hydraulic Power Unit
ITR Inspection & Test Report
P&ID Process & Instrumentation Diagram

1.3 SAFETY
Construction personnel must be made aware of the testing program via the V.L.C.C. safety
meeting and the N.O.E. (Notice ofEnergisation).

The system operational test procedures will detail any specific safety requirements for the
system or sub-system under test, and these shall be complied with at all times in addition to
other project safety codes or standards.

Operational test shall at all times be carried out in accordance with the relevant specification,
codes of practice and statutory regulations, as well as the relevant operational test procedures.

The system under test shall be identified with appropriate signs and barriers. These shall be
used to cordon off the area to prevent those personnel not directly involved in the test from
entering.

The SBM System Responsible Engineer shall ensure there is adequate lighting, ventilation, safe
access and egress, fire fighting equipment and communications provided, and that the wor1< area
is clear of debris

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2. SYSTEM DATA
2.1 SYSTEM DESCRIPTION
The generators are located in the engine room and are equipped with similar starting and
monitoring systems.
Alarms are indicated in the ECR.

2.2 SYSTEM LIMITS

Vendor/Shipyard
Drawing Description Project Dwg. No.
Dwg. No.
Main Steam System 36-101

2.3 SYSTEM DOCUMENTATION

Purchase Order
Title Document No
No.
Refurbishment specification sw 92 191
Makers manual M-404 Box M 16

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3. SYSTEM PRE-REQUISITES
It is the responsibility of the assigned Systems Engineer to ensure the following checks
have been completed:

No. Description Initial

1. Check P&IDs, cable layouts, MCC design, termination etc. (where

applicable) are at the latest revision and marked up with testing
limits.
2. Check that the status of the Inspection & Test Record Sheets (ITR's)
has been checked to ensure that all scope has been completed in
accordance with the Conversion scope.
3. Check that the status of the Refurbishment Tasks Sheets (RTS's)
has been checked to ensure that all scope has been completed in
accordance with the Refurbishment scope (if applicable).
4. All Non Conformance Reports (NCRs) have been cleared.
5. All TQR's associated with this system and associated systems are
reviewed and cleared.
6. All associated systems are available.
7. All spec blinds are correctly positioned and all spec blinds/spades
used for isolation purposes or testing are correctly positioned .
8. Carry out a JSA involving Safety, ABS, Client and the Completions
Engineers.
9. A "line-walk" has been carried out to confirm system status is in
accordance with items 1 to 8 above and that a Punch List has been
issued and agreed with the Operator's representative.
10. Ensure that Shipyard Permit-To-Work System has been reviewed
and is in place prior to commencement of procedure.
System Engineer: (Print)
Signature: IDate:

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3.1 TEST EQUIPMENT AND SPECIAL TOOLS
Instrumentation to demonstrate engine shutdown
Hand held Tachometer
Multimeter

3.2 VENDOR ASSISTANCE

Repair (Stork) representatives in attendance

3.3 COMMISSIONING SPARES AND CONSUMABLES

As Required

3.4 ASSOCIATED SYSTEMSITEMPORARIES

Temporary Power Supplies
Main/Auxiliary/Exhaust Steam System Refer to OTP No. 1503
Main boilers. Refer to OTP No. 1501
Auxiliary condenser.
Seawater Systems Refer to OTP No. 2201
Fresh Water Cooling Water System. Refer to OTP no. 2503

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4. TEST PROCEDURES
Valid work pennits shall be in place prior to commencement of all OTP' s.

Prior to commencement of the procedure the relevant system engineer I supervisor shall
verify the following:

l . System piping (where applicable) "line-up" including temporary piping

equipment and identified on a marked up P&ID.
2. Electrical I Instrument line up and power supply are correct and functional.
3. Temporary systems are functional.

4.1 SCOPE OF WORK AND TEST DESCRIPTION

• Start up and shutdowns tests

• Demonstrate operation of switchboard

• Make Volts and close dead bus.

• Check synchronicity of machine's.

• Check reverse power operation

• Perform load tests as described

4.2 TEST PREPARATION CHECKS

4.2.1 Electrical
No. Steps Initial
1 Confirm all function I pre-commissioning checks have been completed
for the engine control panels required for this test.
2 Confirm all function I pre-commissioning checks have been completed
for the turning gear
Systems Engineer: (Print)
Signature: l Date:
4.2.2 Instruments
No. Steps Initial
1 Confirm all function I pre-commissioning checks have been completed.
2 Confirm all instrument isolation valves are open as per check list
Systems Engineor: (Print)

Signature: 1Date:
4.2.3 Mechanical
No. Steps jlnltialj

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 1 Confirm all function I pre-commissioning checks have been completed.
2 Turbine overhauls have been completed
3 Generator overhauls have been completed
4 Switchboard overhauVmodifications is complete and have been verified
by SBM PC. Engine runs may be commenced prior to switchboard
completion providing necessary precautions are in place
5 All cables and instrumentation checks and tests have been completed
6 Fire precaution have been reviewed necessary action completed
7 Protection tests have been carried out to ensure breaker opening and
turbine shutdowns are functional
8 Ensure outgoing circuits are isolated, locked off and labelled
9 Excitation off
10 Check generator breaker is open and racked out
11 Check cooling systems operational
12 Check generator heaters on
13 All hand valves are in the correct position per P&ID or per any special
commissioning requirement.
Systems Engineer: (Print)
Signature: j Date:
4.3 FUNCTION TESTS
4.3.1 Test Procedures
No. Description No 1 No2
1 Prepare Turbine in accordance to maker's instructions
2 Run Up Turbine in Accordance to maker's instructions
3 Ensure generator breakers are racked in.
4 Excite generator, check voltage readings throughout
system
5 Close generator onto switchboard via dead bus.
6 Check switchboard indications ok
7 Demonstrate turbine shutdown and record results (check
breaker open signal)
8 Close load bank breaker and load generator to 20% load.
Log data
9 Increase load by increments - up to 100%, stabilise
temperatures and pressure vibration at each increment.
Run at 100 %for one hour or until readings stabilise .
10 Reduce load to zero and run to idle for cool down period.
Stop engine
Systems Engineer: (Print)
Signature: I Date:
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7. APPENDIX
Attached
System Drawings
Agreed Final Punch List
Oil Samples - Pre/Post Run (where applicable)
Running & Test Data Sheets

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