1, 180 MW CCPP, BHIKKI

O&M MANUAL CONTENTS

(Draft)

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A. General Introduction of Operation & Maintenance Manual
1. A General Introduction of O&M Manual
1.1 Users Guide
1.2 Plant Overview
1.3 Basic Data and Information of Combined Cycle Power Plant
1.4 Plant Performance
1.5 Safety

B. Operation Manual
1. General of Operation Manual
1.1 General
1.2 Operation Principle
2. Gas Turbine Operation Procedure
2.1 General
2.2 Start-Up
2.3 Synchronizing
2.4 Normal Load Operation
2.5 Remote Operation
2.6 Shutdown and Cool down
2.7 Special Operations
3. Steam Turbine Operation Procedure
3.1 Foreword
3.2 Operation principle
3.3 Basic technical data of steam turbine
3.4 Operation sequence
3.5 Protections logic
3.6 Special sequence
3.7 Trouble shooting
4. HRSG Operation Procedure
4.1 Foreword

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 4.2 Operation principle
4.3 Basic technical data
4.4 Operation sequence
4.5 Protections logic
4.6 Special sequence
4.7 Trouble shooting
5. GT Electrical System Operation Procedure
5.1 General Objective
5.2 Gas turbine generator operation procedure
5.3 Transformer operation procedure
5.4 Emergency diesel generating set system operation procedure
5.5 500KV System operation procedure
5.6 11KV System operation procedure
5.7 400/230V System operation procedure
5.8 DC System operation procedure
5.9 UPS operation procedure
5.10 Motor operation procedure
5.11 Relay protection operation procedure
5.12 PT and CT operator procedure
5.13 Lightning arrester
5.14 Cable operation procedure
6. ST Electrical System Operation Procedure
6.1 General Objective
6.2 Steam turbine generator operation procedure
6.3 Transformer operation procedure
6.4 500KV System operation procedure
6.5 DC System operation procedure
6.6 UPS operation procedure
6.7 Relay protection operation procedure
6.8 PT and CT operation procedure
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 6.9 Lightning arrester
6.10 Cable operation procedure
7. Fuel Gas Booster Station Operation Procedure
7.1 Technical Regulation
7.2 Inspection for Gas Booster Station Starting up
7.3 Check and the Main Operation in Operation
7.4 Gas Booster Station Shut Down
7.5 Setting value
8. Fuel Diesel Oil System Operation Procedure
8.1 Applicable Scope
8.2 Brief Introduction of Fuel Oil System
8.3 Operation Monitoring and Maintenance
8.4 Common Failure Treatment of Fuel System
8.5 Fuel oil system Test and Interlock Protection
9. BOP Operation Procedure
9.1 Nitrogen System
9.2 Hydrogen Generation System
9.3 CCCW System
9.4 OCCW System
9.5 Chemical System
9.6 Fire Fighting System

C. Maintenance Manual
1. General Description
1.1 Purpose
1.2 Maintenance Principle
1.3 Maintenance Classification
1.4 Recommended Rules on Maintenance
2. Maintenance on GT
2.1 Standard Practices

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 2.2 Heavy-duty Gas Turbine Operating and Maintenance Considerations
2.3 Borescope Inspections
2.4 Combustion Inspection
2.5 Hot Gas Path Inspection
2.6 Major Inspection
2.7 Gas Turbine Auxiliaries Maintenance Schedule
3. Maintenance on HRSG
3.1 General
3.2 HRSG Proper And Main Technical Specifications
3.3 HRSG Proper Maintenance
3.4 Pipes And Valves of The Boiler Maintenance
3.5 Valves and Pipes Maintenance Process and Process Methods
3.6 Valves and Pipes Maintenance Quality Standard
3.7 Other Requirements fo Valves and Pipes Maintenance
4. Maintenance on ST
4.1 General
4.2 Steam turbine failures mechanism and maintenance considerations
4.3 Safety precautions
4.4 Steam turbine introduction
4.5 Basic maintenance rules of steam turbine
4.6 Overhaul processes of High and low pressure steam turbine
4.7 Overhaul processes of low pressure steam turbine
4.8 Measure and assembly methods and technical standard for steam
turbine proper parts
5. Maintenance on Chemical Equipments
5.1 Boiler Make-up Water System Maintenance Regulation
5.2 High Temperature Sampling Device Maintenance Regulation
5.3 Hydrogen Generation System Maintenance Regulation
5.4 General-purpose Pump Maintenance Regulation
5.5 Valve and Pipeline Maintenance Regulation
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 5.6 Nitrogen System Maintenance Regulation
5.7 CCCW System Maintenance Regulation
5.8 OCCW System Maintenance Regulation
5.9 Fire Fighting System Maintenance Regulation
6. Maintenance on Electrical Equipments
6.1 Maintenance Cycle and Items
6.2 Risk analysis and Notes
6.3 Preparation for Maintenance
6.4 Maintain Process and Quality Standards of main body of generator
7. Maintenance on Gas Booster

D. Systems & OEM

1 GT
1.1 MAIN TABLE OF CONTENTS
1.2 INTRODUCTION
1.2.1 O&MM user's guide
1.2.2 GE-Supplied equipment general layout
1.3 SAFETY PRECAUTIONS FOR PERSONNEL
1.3.1 Safety precautions for personnel
1.3.2 Information and recommendations about noise
1.3.3 Hazardous areas
1.4 GAS TURBINE
1.4.1 Description
1.4.2 Operation
1.4.2.1 Operation principle
1.4.2.2 Operation sequences
1.4.2.3 Alarms interpretation
1.4.2.4 Special sequences
1.4.3 Performances
1.4.4 Settings
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 1.4.4.1 Device summary
1.4.4.2 Control specification
1.4.4.3 GT incoming air circuit breaker
1.4.4.4 PEECC HVAC
1.4.4.5 PEECC MCC THREE PAHSE UNDER VOLTAGE RELAY
1.4.4.6 GT SITE ALL TEST
1.4.4.7 GCP
1.4.4.8 BENTLEY 3500
1.4.4.9 FIRE PROTECTION PANEL
1.4.4.10 FINAL VERSION OF PID
1.4.4.11 MARK Vie
1.4.5 Maintenance
1.4.5.1 Gas turbine maintenance
1.4.5.2 Gas turbine auxiliaries maintenance schedule
1.4.5.3 Painting specification
1.4.6 Fluid specifications
1.4.7 Bills of material and drawings
1.4.7.1 Foreword
1.4.7.2 Gas turbine instrumentation
1.4.7.3 Gas turbine electrical circuit diagram
1.4.7.4 Fuel nozzle and control assemblies
1.4.7.5 Accessory compartment
1.4.7.6 GT MCC Diagram etc
1.4.7.7 Combustion and turbine casing arrangement
1.4.7.8 Compressor casing and parts
1.4.7.9 Piping arrangements, Modules and Assemblies
1.4.7.10 Heat exchangers, filters, valves
1.4.7.11 Electrical conduit arrangements & assemblies
1.4.7.12 Ignition system and vibration sensors
1.4.7.13 Compressor vane arrangement, unit rotor and coupling
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 assemblies
1.4.7.14 Nozzles and diaphragms
1.4.7.15 Turbine bearings
1.4.7.16 Unit assemblies and enclosure
1.4.7.17 A Turbine optional equipment
1.4.7.18 Jacking oil pump
1.4.7.19 Ventilation fans
1.4.7.20 Fire-fighting system
1.4.7.21 Over head crane
1.4.7.22 GT house air-inlet louvers
1.4.7.23 GT HALL OVERHEAD CRANE
1.4.8 Couplings
1.4.8.1 Load coupling
1.4.8.2 Accessory coupling
1.5 GAS TURBINE AUXILIARY SYSTEMS
1.5.1 Introduction
1.5.2 Gas turbine Instrumentation (control/measuring devices)
1.5.2.1 Control devices-Turbine
1.5.3 Lubricating system
1.5.3.1 Lubricating system
1.5.4 Cooling and sealing air system
1.5.4.1 Cooling and sealing air system
1.5.5 Cooling water system
1.5.5.1 Cooling water system
1.5.6 Gas fuel system
1.5.6.1 Gas fuel system
1.5.6.2 Gas fuel supply
1.5.7 Liquid fuel system
1.5.7.1 Liquid fuel system
1.5.7.2 Light distillate oil forwarding skid
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 1.5.7.3 Light distillate oil filtering skid
1.5.8 Fire detection and protection system
1.5.8.1 Fire detection & protection system
1.5.8.2 Fire protection system
1.5.8.3 Fire protection panel
1.5.9 Inlet bleed heating system
1.5.9.1 Inlet bleed heating system
1.5.10 Hydraulic supply system
1.5.10.1 Hydraulic supply system
1.5.11 Heating and ventilation system
1.5.11.1 Heating and ventilation system
1.5.12 Compressor washing system
1.5.12.1 Compressor washing system
1.5.12.2 Compressor and/or turbine washing skid
1.5.13 Water injection system
1.5.13.1 Water injection system
1.5.14 Inlet guide vanes system
1.5.14.1 Inlet guide vanes system
1.5.15 Inlet and exhaust system
1.5.15.1 Inlet and exhaust system
1.5.15.2 Air filter
1.5.15.3 Exhaust duct overpressure protection
1.5.16 Hazardous gas detection system
1.5.16.1 Gas detection system
1.5.17 Fuel purge system
1.5.17.1 Fuel purge system
1.5.18 Performance monitoring system
1.5.18.1 Performance monitoring system
1.6 GAS TURBINE AUXILIARY SYSTEM MODULES

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 1.6.1 Gas fuel module
1.6.1.1 General arrangement
1.6.1.2 Wiring diagram
1.6.1.3 Instrumentation diagram
1.6.2 Water injection module
1.6.2.1 General arrangement
1.6.2.2 Wiring diagram

1.7 ACOUSTIC ENCLOSURES

1.7.1 Gas turbine enclosure

1.7.1.1 Description
1.7.1.2 Maintenance
1.7.1.3 Drawings
1.7.1.4 Component Literature
1.7.2 Gas module enclosure
1.7.2.1 Description
1.7.2.2 Maintenance
1.7.2.3 Drawings
1.7.2.4 Component Literature

1.8 GENERATOR

1.8.1 Description
1.8.2 Operation

1.8.2.1 General
1.8.2.2 Protection
1.8.2.3 Monitoring

1.8.3 Maintenance

1.8.3.1 General
1.8.3.2 Stator
1.8.3.3 Rotor
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 1.8.3.4 Bearings
1.8.3.5 Coolers
1.8.3.6 Shaft grounding

1.8.4 Drawings

1.9 ELECTRICAL ENERGY EVACUATION

1.9.1 Generator accessory compartment

1.9.1.1 P&ID
1.9.1.2 Safety
1.9.1.3 Description
1.9.1.4 Operation
1.9.1.5 Maintenance
1.9.1.6 Drawings
1.9.1.7 Component Literature

1.10 POWER DISTRIBUTION SYSTEMS

1.10.1 Battery,battery rack and related accessories

1.10.1.1 Safety
1.10.1.2 Description
1.10.1.3 Operation
1.10.1.4 Maintenance
1.10.1.5 Drawings
1.10.1.6 Component Literature

1.11 CONTROL EQUIPMENT

1.11.1.1 Packaged electrical/electronic control compartment (PEECC)

1.11.1.2 Description
1.11.1.3 Operation
1.11.1.4 Maintenance
1.11.1.5 Drawings

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 1.11.1.6 Component Literature
1.11.2 Speedtronic turbine control panel
1.11.2.1 Literature
1.11.2.2 Drawings
1.11.3 Human machine interface
1.11.3.1 HMI literature
1.11.3.2 Historian literature
1.11.3.3 Drawings
1.11.4 Auxiliary panel
1.11.4.1 Drawings
1.11.4.2 Component Literature
1.11.5 Generator protection panel
1.11.5.1 Description
1.11.5.2 Maintenance
1.11.5.3 Drawings
1.11.5.4 Component Literature
1.11.6 EX2100 panel
1.11.6.1 Description
1.11.6.2 Maintenance
1.11.6.3 Drawings
1.11.6.4 Component Literature
1.11.7 Gas detection monitoring system
1.11.7.1 Component Literature

1.12 TECHNICAL INFORMATION LETTERS

2 ST
2.1 ST & auxiliary eqiupments
2.1.1 O&M general description of O&M and document catalogue
2.1.2 Instruction Book for ST proper
2.1.3 Instruction of Lubrication System
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 2.1.4 Instruction of ETS
2.1.5 Instruction of TSI
2.1.6 Instruction of DEH
2.1.7 Instruction of control and protection system
2.1.8 Instruction manual for vibration monitoring and analysis
2.1.9 O&M equipment system instruction of vibration monitoring and
analysis
2.1.10 O&M Instruction of auxiliaries
2.1.11 O&M start up, operation maintenance & inspection manual
2.1.12 O&M List of spare parts
2.1.13 O&M List of special tool
2.1.14 Installation instruction of ST
2.1.15 O&M safety notice
2.1.16 O&M diagram of ST
2.1.17 O&M thermal performance and curve
2.1.18 O&M drawing list supplied with ST
2.2 Main Steam & By-pass System
2.2.1 System description
2.2.2 System PID drawing
2.2.3 Equipment specification
2.3 Gland Steam System
2.3.1 System description
2.3.2 Diagram
2.4 Condensate water system
2.4.1 System description
2.4.2 Drawing
2.4.3 Equipment specifications
2.5 Condenser Extraction Vacuum System
2.5.1 System description
2.5.2 Drawing
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 2.5.3 Equipment specifications
2.6 CW & OCW System
2.6.1 System description
2.6.2 System PID drawing
2.6.3 Equipment specifications
2.6.4 Equipment information
2.7 ST Lube Oil & jacking oil System
2.7.1 System description
2.7.2 System drawing
2.8 Generator hydrogen, water, oil System
2.8.1 Diagram
2.8.2 Equipment specification
2.9 EH oil system
2.9.1 Specification
2.9.2 System diagram

3 HRSG
3.1 HRSG proper
3.1.1 HRSG information
3.1.2 HRSG control and protection description
3.1.3 HRSG installation and operation manual
3.1.4 PID drawings
3.2 Deaerator heating system
3.2.1 System Design Directions
3.2.2 HRSG Deaerator Heating Steam System PID Drawing
3.2.3 Equipment Specifications
3.2.4 Equipments Information
3.3 HRSG HP feed water system
3.3.1 System design directions
3.3.2 HRSG HP feed water system PID drawing

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 3.3.3 Equipment specifications
3.3.4 Equipment information
3.4 HRSG IP feed water system
3.4.1 System design directions
3.4.2 HRSG IP feed water system PID drawing
3.4.3
3.5 HRSG flue gas bypass system
3.5.1 System design directions
3.5.2 HRSG bypass system PID drawing
3.5.3 Equipment specifications
3.5.4 Equipment information
3.6 HRSG drain and blowdown system
3.6.1 System design directions
3.6.2 HRSG drain and blowdown system PID drawing
3.6.3 Equipment specifications
3.6.4 Equipment information
3.7 HRSG hydraulic system
3.7.1 Hydraulic system assemblage drawing
3.7.2 Hydraulic system collocation drawing
3.7.3 Hydraulic system elements drawing
3.7.4 Hydraulic system O&M description

4 Electrical
4.1 GT electrical system
4.1.1 Generator
4.1.2 Electrical Energy Evacuation
4.1.3 Power Distrubution
4.1.4 GCB
4.2 ST Electrical System
4.2.1 Manual of turbine & electric machinery

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 4.2.2 Others
4.3 500kV Electrical System
4.3.1 General drawing
4.3.2 Primary equipment O&M manuals
4.3.3 Protection & control equipment O&M manual
4.3.4 Fault recorder system
4.3.5 Others
4.4 11kV Electrical System
4.4.1 System description and general drawings
4.4.2 Primary equipment O&M manual
4.4.3 Protection and control device manual
4.4.4 11kv ATS
4.5 400V Electrical System
4.5.1 General drawings
4.5.2 Protection device manual operation
4.5.3 400v ATS
4.5.4 Emergency lighting
4.6 Diesel Generator System
4.6.1 Emergency diesel generator sets
4.7 DC System
4.7.1 General drawing
4.7.2 Equipment O&M manual
4.8 UPS System
4.8.1 General drawing
4.8.2 Equipment O&M manual

5 I&C
5.1 Mark VIe
5.2 Maintenance manual for DCS system
5.2.1 DCS-Tech

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 5.2.2 DCS-Drawing
5.3 Manual for DCS system
5.4 Maintenance manual for PLC
5.5 Maintenance manual for IC instrument
5.5.1 Pressure transmitters
5.5.2 Ultrasonic level measurement
5.5.3 Level switch
5.5.4 Meters
5.5.5 Water analysis
5.5.6 CEMC gas analysis
5.5.7 Flow meter
5.5.8 Industrial parameter display

6 BOP
6.1 Compressed air system
6.1.1 System design directions
6.1.2 Compressed air system PID drawing
6.1.3 Equipment specifications
6.2 Domestic water system
6.2.1 System design directions
6.2.2 Equipment specifications
6.2.3 Equipment information
6.3 CCW system
6.3.1 System design directions
6.3.2 CCW system PID drawing
6.3.3 Equipment specifications
6.3.4 Equipment information
6.4 CCCW system
6.4.1 System description
6.4.2 PID drawing

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 6.4.3 Manufacturers specifications
6.5 Demineralization water system
6.5.1 Demineralization water system PID drawing
6.5.2 Equipment specifications
6.5.3 O&M
6.6 Waste water treatment system
6.6.1 System design directions
6.6.2 Waste water treatment system PID drawing
6.6.3 Equipment specifications
6.6.4 Equipment information
6.7 Steam-water supervision system
6.7.1 Operation of water-steam integrated sampling device
6.7.2 Operation of chemical feeding system
6.7.3 Chemical supervision during unit start up
6.7.4 Chemical monitoring during unit operation
6.7.5 Water-steam test method
6.8 Main power area and circulation water dosing system
6.8.1 System design directions
6.8.2 Dosing system PID drawing
6.8.3 Equipment specifications
6.8.4 Equipment information
6.9 Hydrogen generation system
6.9.1 System design directions
6.9.2 Hydrogen generation system PID drawing
6.9.3 Equipment specifications
6.9.4 Equipment information
6.10 HAVC system
6.11 Bridge crane
6.12 Electro-chlorination system
6.13 Nitrogen system
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 6.14 Natural gas compressor
6.14.1 Motor
6.14.2 Compressor
6.14.2.1 Compressor specification
6.14.2.2 NG booster
6.14.2.3 Compressor mechanical diagram
6.14.2.4 Compressor I&C diagram
6.14.3 Dry seal
6.14.3.1 Gas seal specification
6.14.3.2 Diagram

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