E0430 Commissioning Manual

Solar Turbomachinery
PD# 2-E0430
CUSTOMER: PEMEX
SITE: AKAL-C6
Commissioning Manual /
Checklist with
Acceptance Documentation
Controls Retrofit and Expanded Services
Compressor Set
FEBRUARY 2007
Caterpillar: Confidential Green

Solar Turbines Incorporated
92186-5376
. P.O. Box 85376 . San Diego , CA.
PROPRIETARY NOTICE
The contents of this technical publication are proprietary data of Solar

Turbines Incorporated, a subsidiary of Caterpillar Inc. Reproduction or
use of any part for other than the Commissioning and Acceptance of the
Solar Turbine Equipment is permissible only if expressly authorized in
writing by Solar.
2
FOREWORD
To: Solar Turbines Field Service Reps.
1. After you have completed this Manual, please distribute it as follows:

2. Scan or fax the following to your CSPM Commissioning Project Support Engineer at
(858) 694-6801
PART 1
Customer Acceptance
Customer Commissioning Survey
Start-up FSR Shipping Evaluation Form
PART 2
Acceptance/Discrepancy Audit. This is the punch list that still must be resolved at
the time of customer acceptance or when the package first demonstrates beneficial use. The
project will remain active until all items have been resolved. If there is no punch list, Project
Management will close the project work order.
3. Give a copy of the manual to the customer, if desired.

4. Forward the completed manual to your District Service Manager to retain with
Customer files.
5. As-installed drawings - send to Commissioning Project Support Engineer including
sheet 1 and all sheets with changes marked, red for deletions and green for additions.
6. As-installed software - uploaded to the FOW, send e-mail from the FOW to “T3 Field
Return Software”, cc PM and CPSE.
3
Have a great startup.
The words SOLAR, SATURN, CENTAUR, TAURUS, MERCURY, MARS, TITAN and
TURBOTRONIC are Trademarks of Solar Turbines Incorporated, a subsidiary of
Caterpillar Inc.
S:/CSPROJ/Commissioning:/ Retrocommiss/Manual_02_07
COMMISSIONING CHECKLIST AND CUSTOMER ACCEPTANCE
CUSTOMER CONTACTS
CUSTOMER NAME AND BILL TO ADDRESS CUSTOMER NAME AND BILL TO ADDRESS
CUSTOMER ENGINEER: CUSTOMER SITE SUPERINTENDENT:

NAME: NAME:
PHONE #: ( ) PHONE #: ( )
FAX #: ( ) FAX #: ( )
CUSTOMER LOCAL SITE OPERATOR: CUSTOMER LOCAL SITE OPERATOR:
NAME: NAME:
PHONE #: ( ) PHONE #: ( )
FAX #: ( ) FAX #: ( )
PRIME CONTRACTOR
NAME AND ADDRESS: SITE SUPERINTENDENT:
NAME:
PHONE:
4
SUBCONTRACTOR COMPANY NAMES AND SITE FOREMAN NAMES
SURVEYOR COMPANY: SITE FOREMAN / PHONE:
MILLWRIGHT COMPANY: SITE FOREMAN / PHONE:
PIPEFITTER COMPANY: SITE FOREMAN / PHONE:
WELDER COMPANY: SITE FOREMAN / PHONE:
COMMISSIONING CHECKLIST AND CUSTOMER ACCEPTANCE
CUSTOMER CONTACTS
SUBCONTRACTOR COMPANY NAMES AND SITE FOREMAN NAMES
BUILDING COMPANY: SITE FOREMAN / PHONE:
ELECTRICAN HIGH VOLTAGE CO: SITE FOREMAN / PHONE:
ELECTRICAN LOW VOLTAGE CO: SITE FOREMAN / PHONE:
INSTRUMENT & TUBING CO: SITE FOREMAN / PHONE:
SOLAR – SAN DIEGO CONTACTS

COMMISSIONING PROJECT SUPPORT
PROJECT MANAGER:
ENGINEER:
NAME Sergio Ruiz-Castillo – Latin America,
NAME: OSCSR GONZALEZ
Western US & Canada, AP N & S)
PHONE #: (858) 694-6719 PHONE #: +1 858 694-6126
FAX #: (858) 694-6860 FAX #:
LOCATION: CSC 14 LOCATION:
NAME: Steve Atherton (EAME, Eastern US &
Canada
PHONE #: (858) 694-6417
FAX #: (858) 694-6860
LOCATION: CSC 15
NAME:
PHONE #:
5
FAX #:
LOCATION:
SPECIAL INSTRUCTIONS OR OTHER RELEVANT INFORMATION
PART 1
CUSTOMER ACCEPTANCE
WARRANTY DATA
EQUIPMENT IDENTIFICATION
CUSTOMER COMMISSIONING SURVEY
START-UP FSR ASL EVALUATION FORMS
Instructions
PART 1 Contains all necessary data to document official Startup acceptance and initiate
warranty.
Final Customer Acceptance – This portion of Part 1 requires the signature of the Customer or
his authorized representative. This signature indicates customer’s acceptance of the equipment,
subject to any discrepancies recorded under Part 2 of this document.
Warranty Data – The Solar representative shall enter ONLY the customer acceptance and first
beneficial use dates. Only the Warranty Administrator is authorized to determine the warranty
expiration date (upon receipt of a copy of this document in San Diego) based on extended
warranty terms or the following standard formula:
“The Standard Warranty period for a Gas Turbine Package is 12 months from the date of first
use, or 18 months from the date of shipment by Solar Turbines Incorporated, whichever shall
occur first.”
In those cases where the customer has purchased long-term package preservation, the customer
must purchase or have written into the sales agreement any warranty beyond the 12 or 18 month
dates listed above.
6
Note
Requests for extended warranty coverage
should be directed to Solar District Service Manager.
Note
Buyer (User) acceptance occurs when the Buyer (User) receives first
beneficial use from the equipment provided, or when the equipment
has demonstrated such capability at site.
Equipment Identification Data – This information is to be completely filled out by the Solar
Representative, if the Solar Commissioning Project Support Engineer has not previously entered
the data. Enter N/A in all spaces not applicable to the equipment being commissioned.
Customer Commissioning Survey – filled out by Customer and forwarded by the FSR.
Start-up FSR Shipping Evaluation – filled out by FSR.
EQUIPMENT COMMISSIONING CHECKLIST

AND CUSTOMER ACCEPTANCE
Customer Acceptance
CUSTOMER:___________________________________________________SITE:__________________________________
STARTUP/COMMISSIONING COMPLETED AND EQUIPMENT ACCEPTED BY CUSTOMER, SUBJECT ONLY TO THOSE
DISCREPANCIES RECORDED ON THE ATTACHED PUNCH LIST. CUSTOMER ACCEPTANCE ACKNOWLEDGES THAT
EQUIPMENT HAS PROVIDED FIRST BENEFICIAL USE, OR DEMONSTRATED SUCH CAPABILITY AT SITE.
_____________________________________________________ _______________________ _______________

CUSTOMER REPRESENTATIVE TITLE DATE
Warranty Data
CUSTOMER ACCEPTANCE DATE: _______________ SHIPMENT DATE: ________________________

FIRST BENEFICIAL USE DATE: __________________
STANDARD WARRANTY EXPIRATION DATE:_____________________________________________________________
Solar Warranty Administrator, San Diego
EXTENDED WARRANTY EXPIRATION DATE:_____________________________________________________________

Solar Warranty Administrator, San Diego
TERMS:_____________________________________________________________________________________________
7
Equipment Identification
END USER: _______________________________________________ DATE:____________________________________
CUSTOMER COMMISSIONING SURVEY

CUSTOMER REP:___________________________________________
GEAR UNIT MANUFACTURER:
SOLAR PROJECT
SOLAR REP. NAME: _________________________ ____________________________________
_______________________________________________ SOLAR PD #: _____________
Please rate each of the following areas, as applicable, on a scale

GEARof one ________________________
RATIO: (very dissatisfied) to
five (very satisfied) or N/A by circling your choices. Please feel free to comment relating to
CUSTOMER ORDER: ________________________________________ S/N:_________________________________
the scores. Thanks in advance for your valuable feedback about our product(s).
SALES ORDER / PD#: _______________________________________ DRIVEN EQUIPMENT TYPES :
1. "AS SHIPPED" SOFTWARE: N/A 1 2 3 4 5
(1)__________________________________
MODEL: __________________________________________________ S/N:_________________________________
2. "AS SHIPPED" DRAWINGS: N/A 1 2 3 4 5

PACKAGE S/N: _____________________________________________ (2)__________________________________
TURBINE S/N: ______________________________________________ S/N:_________________________________
3. CONDITION OF “PRODUCT”: N/A 1 2 3 4 5

(3)__________________________________
4. PACKING LIST: N/A 1 2 3 4 5
5. COMPLETENESS OF “PRODUCT”: N/A 1 2 3 4 5
6. ANCILLARY COMPONENTS: N/A 1 2 3 4 5
7. COMMUNICATIONS WITH SOLAR: N/A 1 2 3 4 5
8. EXPERTISE OF SOLAR’S SITE PERSONNEL: N/A 1 2 3 4 5
9. MAINTENANCE MANUAL AND PARTS LIST: N/A 1 2 3 4 5
8
Customer signature: ________________________________Date : ______________
Address/ phone number: _________________________________________________
Start-up FSR Shipping Evaluation Form
Project Name: _______________________ PD#: _____________________
Please rank each of the following categories on a scale from 1 (very bad) to 5 (very good) or
N/A. In addition, please feel free to provide comments regarding each category.
1. Overall Shipment Accuracy N/A 1 2 3 4 5
2. Kit(s) Accuracy N/A 1 2 3 4 5
3. Shim Kit(s) Accuracy N/A 1 2 3 4 5
4. Interconnect Hardware Accuracy N/A 1 2 3 4 5
5. Ancillary Accuracy N/A 1 2 3 4 5
6. Quality of Shipment Packing N/A 1 2 3 4 5
Please provide detailed list of all loose ship items that you EXPECTED to receive but did
NOT. Please include quantities and reason for need.
Part Number (if Description Qty. Reason for Need
known)
Please provide detailed list of all loose ship items that you received but did NOT need.
Part Number Description Qty.
9
Please return completed form to Commissioning with the as-installed drawings, etc.
Commissioning will forward to the 6 Sigma Shipping Team Leader.
10
PART 2
DISCREPANCY / RESOLUTION
Instructions
All major discrepancies encountered during commissioning and resolutions or corrective

actions taken shall be recorded. Each discrepancy shall be logged on the Audit Sheet and a
number assigned. Discrepancy/Resolution sheets shall be signed off by appropriate Solar
Representative, and where applicable for concurrence or acceptance of responsibility, by the
customer or his designated representative.
Discrepancy Audit Sheet (Page 12)
A discrepancy audit sheet is provided to record and track the discrepancy / resolution reports.
Each report will be issued an Item Number. The Item No., Description, Date Resolved and sign
off shall be recorded. The Solar Representative shall initial the appropriate column when the
discrepancy is resolved and have it signed-off by the customer or his designated representative.
Discrepancy / Resolution Report – General (Pages 13 to 17)
All major discrepancies encountered during Commissioning and resolutions or corrective actions
taken shall be recorded. Additional pages, identified by the particular commissioning procedure,
may be attached to record additional actions required or taken. All additional pages attached shall
be dated, and signed by the Solar Representative. Attached sheets shall contain the Item No. of
the Record Sheet to which they are attached. Discrepancy / Resolution sheets shall be signed off
by appropriate Solar Representative, and where applicable for concurrence or acceptance of
responsibility, by the customer or his designated representative.
Discrepancy / Resolution Report – Electrical Conduit Sealing (P18-19)
On units requiring E.P. Class 1, Division 1, Group D Electrical System, if the Customer
Representative/Contractor declines to install, or to have Solar install, the electrical conduit
sealers per SOLAR SERVICE BULLETIN 5.OCS/103A, this form MUST BE COMPLETD
and signed and dated by Customer’s Representative/Contractor, and witnessed-signed-dated by
appropriate Solar Representative. The Customer Representative/Contractor shall then assign a
date as to when the above will be accomplished and sign-date same.
STANDARDS AND CODES:

 Solar Specifications 1593, 1604, and 2017.
11
 National Electrical Code (NEC), Article(s) 500, 501, 502.
 Canadian Standards Association (CSA).
 Canadian Electrical Code (CEC), Part 1.
 ES 9-98 Solar Quality Requirements for Fuel, Air and Water/Stream.
 ATEX
CSPM COMMISSIONING
ACCEPTANCE / DISCREPANCY
AUDIT
CUSTOMER: _____________________ SITE:_____________________
LOCATION:____________________________________________________________
SOLAR REPRESENTATIVE:_________________DATE:______________________
ITEM DATE SOLAR REP.

DESCRIPTION OF DISCREPANCY
NO. RESOLVED INITIAL
12
SOLAR REPRESENTATIVE SIGNATURE:_________________________________
CSPM COMMISSIONING
RESOLUTION REPORT
DATE:__________________ ITEM NO.___________________________
COMMISSIONING PROCEDURES
DISCREPANCY / RESOLUTION REPORT
DISCREPANCY:_____________________________________________________________
DESCREPANCY DESCRIPTION:
________________________________
SOLAR REPRESENTATIVE /DATE
_____________________________________________________________________________
13
RESOLUTION:
EVERYTHING STATED IN RESOLUTION BOX HAS BEEN COMPLETD AND ACCEPTED.
________________________________ ____________________________________
SOLAR REPRESENTATIVE CUSTOMER REPRESENTATIVE
CSPM COMMISSIONING
RESOLUTION REPORT
DATE:__________________ ITEM NO.__________________________
DISCREPANCY:_____________________________________________________________
14
________________________________
_____________________________________________________________________________
RESOLUTION:
________________________________ ____________________________________
CSPM COMMISSIONING
RESOLUTION REPORT
DATE:__________________ ITEM NO.__________________________
DISCREPANCY:_____________________________________________________________
15
________________________________
_____________________________________________________________________________
RESOLUTION:
________________________________ ______________________________
CSPM COMMISSIONING
RESOLUTION REPORT
DATE:__________________ ITEM NO.___________________________
DISCREPANCY:______________________________________________________________
16
________________________________
_____________________________________________________________________________
RESOLUTION:
________________________________ ____________________________________
CSPM COMMISSIONING
RESOLUTION REPORT
17
DATE:__________________ ITEM NO.___________________________
DISCREPANCY:_____________________________________________________________
________________________________
____________________________________________________________________________
RESOLUTION:
________________________________ ________________________________
CSPM COMMISSIONING
18
RESOLUTION REPORT FOR
ELECTRICAL CONDUIT SEALING
DATE:__________________ ITEM NO.______________________
DISCREPANCY: Customer does not wish the conduit seals poured at this time.
SAFETY COMPLIANCE: Engine Crank and Light-off
CUSTOMER HAS DECLINED TO HAVE ELECTRICAL CONDUITS SEALED IN

ACCORDANCE WITH THE ABOVE AND SOLAR SEVICE BULLETIN 5.OCS/103A.
CUSTOMER DECLARATION
WE HEREBY RELIEVE SOLAR OF THE RESPONSIBILITY FOR SEALING THE ELECTRICAL CONDUITS
ON THIS PACKAGE. THE SEALING WILL BE ACCOMPLISHED BY US OR OUR CONTRACTOR. WE
HEREBY ACCEPT FULL RESPONSIBILITY FOR THIS ACTION AND AGREE TO RELIEVE AND HOLD
SOLAR TURBINES INC. HARMLESS FROM ANY AND ALL LIABILITIES ARISING FROM THE SEALING
(OR LACK THEREOF) OF ELECTRICAL CONDUITS.
_________________________________
Customer Representative / Date
___________________________
Solar Representative /Date
______________________________________________________________________________
RESOLUTION:
Customer to complete the sealing of all electrical conduits in accordance with Solar Service
Bulletin 5.OCS/103A on or before the following date:
______________________________________
Date assigned by Customer for resolution
________________________________
19
CSPM COMMISSIONING
RESOLUTION REPORT FOR
DATE:__________________ ITEM NO.______________________
DISCREPANCY: Customer does not wish the conduit seals poured at this time.
SAFETY COMPLIANCE: Pre-shutdown checks, shutdown & post operation

Procedures
CUSTOMER HAS DECLINED TO HAVE ELECTRICAL CONDUITS SEALED IN

ACCORDANCE WITH THE ABOVE AND SOLAR SEVICE BULLETIN 5.OCS/103A.
CUSTOMER DECLARATION
WE HEREBY RELIEVE SOLAR OF THE RESPONSIBILITY FOR SEALING THE ELECTRICAL CONDUITS
ON THIS PACKAGE. THE SEALING WILL BE ACCOMPLISHED BY US OR OUR CONTRACTOR. WE
HEREBY ACCEPT FULL RESPONSIBILITY FOR THIS ACTION AND AGREE TO RELIEVE AND HOLD
SOLAR TURBINES INC. HARMLESS FROM ANY AND ALL LIABILITIES ARISING FROM THE SEALING
(OR LACK THEREOF) OF ELECTRICAL CONDUITS.
_________________________________
___________________________
Solar Representative /Date
________________________________________________________________________
RESOLUTION:
Customer to complete the sealing of all electrical conduits in accordance with Solar Service
Bulletin 5.OCS/103A on or before the following date:
_____________________________________
Date assigned by Customer for resolution
20
________________________________
COMMISSIONING PHILOSOPHY
Subject: Commissioning Tasks and Schedule
This is a general guide about the effort needed to commission Solar Turbines packages.
If a particular section has not been affected, please disregard.
SAFETY FIRST
Table of Contents
PRELIMINARY ACTIVITY
ON SITE ACTIVITY
Sort and Inventory Loose Ship

Oil Tank Vent System
Lubricating Oil System
Lubricating Oil Flushing
Alignment
Enclosure and Ancillary Equipment
Package Drain and Vent Systems
Electrical Ground System
Battery Chargers, 24 and 120 VDC
Main Control Console
Remote Console (Optional)
Turbine Inlet Guide Vanes and Bleed Valve
Fuel Gas System/Pneumatic Oil Pump Supply
PECC Valves
Enclosure Fire and Suppression System
Enclosure Gas Monitoring System
Air Inlet System
Exhaust System
Waste Heat Option
Water Wash System
Compressor Seal Oil System/Buffer Gas System/Dry Seal System
First Compressor Train/Yard Valves/Pipe Valve Skid Pressurization
Prepare Pipe Valve Skid for Pressure Test
Generator Sets
Start System
First Engine Crank and Light-Off
21
On-Line/Operational Checks
SoLoNOx Field Commissioning Setup
Shutdown and Post-Operational Procedures
FSR Completion of Paperwork
22
PRELIMINARY ACTIVITY
 Get a shipping address/procedure/custom’s requirements to send parts and support

tooling to site. Include “attention to” name and site telephone number.
 Ensure tooling for start-up is available. Who is supplying alignment tool?
 Is a flush kit needed? Where is it and can it be used during commissioning? Has a
contractor been hired to flush off-skid piping and cooler if needed?
 Review vendor data and vendor support personnel requirements.
 Review the condition of the package.
ON-SITE ACTIVITY
 Keep your Commissioning Project Support Engineer informed of on-site

activity/emergencies.
 Include PD number, project name, and problem in subject line of e-mail.
Sort and Inventory Shipment
 Ensure parts are stored in a reasonable/logical manner. If they cannot be kept dry and
secure, inform DSM and Commissioning.
 Identify and report any missing parts as soon as possible.
 Inspect for shipping/installation damage and make note on carrier’s Bill of Lading, if
possible. Report findings to DSM and Commissioning.
 Inspect interconnect shafts for complete assemblies, including bolts, shim packs, etc.
Record serial number which must be the same on all pieces.
 Inspect batteries for electrolyte. Solar’s standard is wet. If the customer insisted on dry
batteries, verify that he has arranged for electrolyte.
Oil Tank Vent System
 System installed per drawing. Flame arrester installed (within 15 ft. of pipe termination).
 Check for the correct clearances for future maintenance access. Example: Demister
trapped under roof? Ensure there is enough clearance to service.
 All pipes clean. The vent pipe is part of the turbine lube oil system.
23
Lubricating Oil System
 Inspect off-skid pipes, vents, drains and coolers per drawing. Solar strongly
recommends stainless steel piping to ensure a clean oil system.
 Lube system per drawing? Note position of orifice plates in supply lines, if used.
 Install loose ship items (optional).
 Verify that all filter elements are correctly installed in all filter housings.
 Visually check all pumps for proper rotation and pressure to ensure arrows are not wrong.
 Check logic for proper lube oil pump operation under all operating conditions. Example:
Ten second time delay in logic before backup pump starts after a power failure.
Lubricating Oil Flushing
 See ES 2184 Cleaning and Flushing of Hydraulic Systems Components.
 Check L/O tanks for water or debris.
 Lube Oil Coolers provided by U.S. companies are certified to be flushed but take a close
look inside their ports.
 Cheaper flushing oil can be used, but care must be taken that the oil is compatible with
the oil used for service. Any residual flushing oil left in the system will also dilute and
degrade the service oil. The oil supplier should be able to address the oil compatibility
issue. The oil used for service must also be filtered to achieve the required oil
cleanliness.
The service oil can be used for flushing the package and off skid system, and most of the
time this oil is still serviceable for package operation. Steps taken to clean the site
erected piping, use of clean assembly and preservation practices, removal of any water
used for hydro testing, etc., will increase the possibility of using the service oil for
flushing and service. Some of the additives in the oil's additive package such as the anti
foam additive may coat new metal surfaces or have a polar bond and get tied up with
water. The oil supplier should be queried about how to determine if the oil is still suitable
for use.
Usually AC motor driven main lube oil pumps provide enough flow capacity so they can
be used for flushing. The pre/post pumps can provide enough flow for many line sizes.
The main concern will be the pressure drop through the flushing loop and whether the
pre/post pumps can provide enough flow to be used for flushing. Another concern is the
modifications required to the package piping to be able to use the package pumps for
flushing the off skid piping, etc., without including the package piping in the flush loop.
24
 Always use external filters for flushing. The on-skid filters are not suitable
for this purpose. Ideal is 3 micron filters but 5 micron will do as well. Check
viscosity and flow parameters to determine filter size.
 It is most important to use a 3-micron filter for filling the lube oil tank.
Alignment
 Must be done prior to installing/connecting headers and inlet/exhaust system ducting. On

Titan and Mars, install exhaust bellows per alignment section of MI drawing before
alignment.
 Lubricate bearings. Temporary power supply to lube oil pump can help.
 Final alignment after header and piping.
 Start with fixed component (Compressor/Gearbox). Follow instructions in MI drawing.
 Use proper tooling.
 Check total distances first and last.
 On Generators, magnetic center on the generator must be used.
 Inspect magnetic speed pickups.
 Install interconnect shafts and housings.
 Check coupling vents and drains.
 Remove flexible disc coupling locks-crews (red/yellow) and save for future use. Follow
vendor drawing. Kop-Flex coupling will fail if screws are left in.
Enclosure and Ancillary Equipment
 To prevent failures with the Quantum Premier controller, pull the fuse out of UCP for
Quantum Controller. Then the controller will not be powered up until all welding,
cabling, termination work and loop check are finished. If possible, put the fire system as
the last commissioning task after finishing all other loop checks and before starting up the
turbine.
 Verify interface between skids and loose ship items.
 Verify air filter wire routing. Do this early.
 Inspect electrical equipment and lighting. Connect enclosure lights.
 Inspect installation and operation of enclosure ventilation system, motor rotation, etc.
25
 Inspect fire system for correct mechanical installation. (On and Off skid)
 Inspect gas detection system for correct mechanical installation.
 Inspect fire shutter system for correct mechanical installation.
 Cover fire eyes during construction.
Package Drain and Vent Systems
 Inspect all drains per drawing/specification.
 Flame arresters are installed per drawing. Standard is installed vertical. Horizontal
installation is optional and requires a drain to tank be installed.
 Think Safety. No rain hat on pneumatic start vent. Pay attention to where it is venting.
 Do not allow PCD/exhaust overboard to vent to combustibles.
Make sure oil tank drain shutoff valve is fitted.
No hand valves are to be installed in drain lines with no back pressure requirement.
26
Electrical Ground System
 Check that all equipment is grounded per spec/drawing.
 The I/S ground must be directly connected to that ground point. Physical earth (PE) and
instrument earth could be connected together if the location has a good, clean ground.
Intrinsically Safe (I/S) barriers depend on a potential free ground.
It is best not to tie grounds together at the console. They should leave the console
to the customer ground as three different ground cables.
Battery Chargers, 24 and 120 VDC
 Ensure site has correct A.C. voltage to charger and correct charger part number. Do this
early. Check jumpers in the battery charger for proper input voltage setup.
 Verify that chargers are installed/operating per drawing manuals and that batteries are
filled to the proper level.
 Check float rate/high rate set points. Most chargers are factory set for lead acid batteries.
See SB 5.9/103A.
 Inspect interconnect to turbine systems and consoles.
First NiCad charging. The vents will be closed during charging. The first
charging should be made at a constant current. The recommended current is 0.2 x
C amperes, where C is the rated battery capacity in ampere-hours. Multiplying
the charge rate times the charge time gives the total charge in ampere-hours. A 10
hour charging period at a 0.2 x C rate will give the recommended charge of 2 x C
ampere-hours. Other charging current rates between 50% and 150% of the
recommended charging current may be used if the charge time period is adjusted
to still give the recommended total charge of 2 x C ampere-hours. In most cases,
the rectifier high-rate or boost charging voltage is not high enough to keep the
charging current at the recommended level during the whole charging period.
Most chargers provided by Solar are current limited at approximately 110% of the
nameplate ampere rating. In this case, connect the charger to only 2 of the cells
provided. The charging period and recommended constant current remain
unchanged. The current limiting feature of the battery charger will adjust the
voltage as required. Repeat the process for the second half.
Example: Solar part number 120362-100 is a 256 ampere-hour 10-block battery

assembly. The recommended first charge process is a current of 51 amperes
(0.2 x 256) for 10 hours for a total of 512 ampere-hours (2 x 256 or 10x51).
Charge 5 block (1/2 of 10) at 51 amperes for 10 hours or any other rate and
27

time combination between 25 amperes (50% of 51) and 76 amperes (150% 0f
51) that produces a total of battery performance.
 Wait at least two hours after charging before adjusting the electrolyte level.
Electrolyte should be added or removed so that the cell oil surface reaches the maximum
level line.
 The battery is now ready for use. No electrolyte should be added later. For normal
topping, only distilled or deionized water should be used.
Main Control Console
 Check for grounds / gross errors before console power-up.
 Install low watt heater system to dry out console, if required
 Disconnect all PC boards - i.e., swing arms, to protect them during welding.
 Inspect for correct D.C. polarity and voltage from battery chargers.
Example: 120 AC/DC on 24 DC will cause smoke
 Tag out heaters, coolers, pumps and valves prior to powering up the console.
 Check for separate power source to backup board if supply is customer provided.
 Check total interconnect length and wire sizes.
 Record Series and Rev numbers of all cards for your records.
 Inspect interconnects.
 Disconnect fire CO2 system control heads.
 Power up the console. Install As-shipped software.
 Perform power-on loop checks. Highlight schematic as each loop is checked.
 Perform static checkout of all systems. Such as:
1. Temperature and pressure systems.

2. Speed systems.
3. Vibration system.
4. Fire system.
5. Gas detection system.
6. Surge system.
7. Yard valves.
28

8. Emergency shutdown (ESD).
Remote Console (optional)
 Inspect for correct D.C. polarity from battery chargers.
 Inspect interconnects.
 Power up the console. Install software.
 Connect and test line printer (optional). Is correct paper available?
Turbine Inlet Guide Vanes and Bleed Valve
On Skid.
 Check all components for mechanical integrity.
 Check on skid wiring and interconnect to control console.
 Verify polarity is correct.
Control Console.
 Check wiring from back up system to interconnect.
 Simulate guide vane/bleed valve operation
 Verify that all operations are correctly sequenced and feedback signals are correct.
 Remove test equipment from skid and console.
Fuel Gas System/Pneumatic Seal Oil Pump Supply - Ensure that customer’s gas is clean
before proceeding. THINK SAFETY
On Skid.
 Functional check of system. Ensure primary valve will close with vent valve open.
 Inspect gas vent system.
 Leak check system
Off Skid.
 Blow down, or clean by other method, piping to skid edge. Temporary blow down
29

manifold may be needed.
 Ensure correct strainer installed. See S.B. 2.1/106A.
 Inspect for clean gas supply system. If clean gas is not guaranteed, recommend customer
to install 10-micro filter and advise fuel injectors are not fuel filters.
 Check for correct pressure and temperature of gas at skid edge per drawing.
Water Injection System. The seal used in the CAT pump requires a few drops of a light oil (3-
in-1) once a month or it will leak. Option is to install grease fittings and grease.
CCC/ PECC Valves. Before proceeding, check these Service Bulletins that pertain to CCC/
PECC Fuel valves: 5.0/111A, 5.1/140, 5.9/104B. Also see 3.1/109 about signal loss due to
welding, etc.
Enclosure Fire and Suppression System
 Inspect all interconnects, console, skid and bottles.
 Function test system but stop before discharging bottles.
 Trip shutters with air supply
 Connect control heads after all testing is completed.
 Check for correct zoning of fire eyes, if equipped.
 Check impedance of cards.
30

Enclosure Gas Monitoring System
 Inspect interconnect from skid to console.
 Function test system.
Air Inlet System
A. On Skid.
 Clean and inspect to ensure assembled per drawing.
 Check drains for proper connection, if needed.
B. Off Skid.
 Inspect inlet system for shipping installation damage.
 Inspect air inlet silencer prior to installation.
 Verify that system has been assembled per drawing, and elements are installed.
 Visually inspect all ducts for correct sealing.
 If customer-supplied, is design/material thickness ok? Is manway installed, if needed?

Do not let customer use air conditioning ducting as an air inlet.
Exhaust System
 Check for correct assembly per drawing. Use rubber mallet to seat marmon clamp.
 Clean system. Check for cracks, especially on CED units.
 Connect / inspect drain system.
 Ducting thermal growth controlled within limits.
 Fire protection for roof penetration (wood).
 Exhaust growth can cause vibration due to misalignment.
 Bellows in shipping braces are not the correct installation length. Check MID for
required installed length.
31

 Verify proper support of exhaust ducting.
Waste Heat Option
 Flameout kit on the turbine package (PCD pressure switch) is required with use of a WHRS.
Outputs from Unit Control Panel:
 Start WHRS purge

 Turbine shutdown
 90% Ngp speed
Inputs to UCP:
 Summary permissive
 WHRS purge completed
 WHRS malfunction (alarm only)
 Diverter valve malfunction (turbine shutdown)
Sequence of Operation:
 Initiate start from console start button.

 Start permissive to WHRS panel.
 Begin purge timer in UCP. Verify timer length does not exceed starter motor duty
cycle.
 Begin purge timer in WHRS.
 During purge, the diverter valve begins in the bypass position and is cycled by the
WHRS panel to purge all ducts.
 WHRS purge complete signal to UCP.
 Continue turbine start sequence.
 Ninety percent NGP signal from UCP allows WHRS to initiate boiler/heat recovery
operation (diverter valve from bypass to open).
Water Wash System
32

On skid
 Perform final cleaning and inspect all ducts.
Off Skid
 Clean water supply. See ES 9-247.

 Inspect off skid piping, if installed. Flush with water prior to use.
Compressor Seal Oil System/Buffer Gas System/Dry Seal System
Wet Seals – Reference SB 13.2/109, TL 13.2/103 and TL 13.2/118 for details
 Check oil level in seal oil traps

 Verify that filter elements are correctly installed in all filter housings.
 Check for presence of engine driven seal oil pump shaft.
If low or no pressure, verify that coupling is installed.
 Check rotation/operation of A.C. seal oil pump.
 Check operation of pneumatic seal oil pump.
 Set pressure control valves per hydro mechanical drawing.
Buffer Gas System
 Blow down /clean from piping to skid edge.

 Verify that gas strainer is installed.
Dry Seal System
 Verify filters are installed.

 Buffer gas source must be clean and dry with the correct temperature and pressure
at skid edge.
 Buffer air system fail safe and all valves open.
 Correct buffer air supply pressure.
 Must have buffer air when compressor case pressure is present or a lube oil
command is called.
GAS Manual. A comprehensive source and worth checking when in the district office.
Solarweb.solar.cat.com/dept/tmp/cat-green/GC/cover.html
First Compressor Train/Yard Valves/Pipe Valve Skid Pressurization
 Verify surge valve I/O is an independent loop and not in common with other I/O.
 Verify correct surge valve by part number or specs with the surge control drawing.
 Verify that no gas is present behind suction/discharge valves so that all valves can be
safely operated from the main control console.
 Check skid per drawing.
 Check electrical interconnect to control console.
 Ensure there is a delta P switch, transmitter, or gage across suction strainer to fast stop the
package in event of a clogged suction strainer.
 Check skid vent and drain system.
 Verify that process piping has been blown down or cleaned by some other method.
 Check all motors for correct voltage and frequencies.
 Surge control pressure taps must not be upstream or downstream of any obstruction in the
process piping. Example: Upstream of a suction strainer.
Prepare pipe valve skid for pressure test.
 Verify correct valve action during microprocessor fail.

 Verify that the suction, discharge and loading valves are closed and vent and bypass
valves are open.
 Verify that buffer gas is available and that the seal oil system is ready for operation.
 Open loading valve manually and purge skid. Close the vent valve and pressurize the skid
in steps. Stop at several points and check for leaks or other problems.
 Verify that the seal oil and lube oil pumps start as soon as gas pressure starts to build up.
 Hold pressure for ½ hour. Check for correct seal oil and buffer gas pressure.
 Depressurize system.
Generator Sets
 LOCKOUT procedure is in place and followed. Ensure it is adequate.
 Ensure during alignment that the “Hub to Hub” distance is first set with the generator
shaft positioned at its magnetic center. Recheck this distance when taking final alignment
readings. Check drawing/manual for coupling and shear bolt installation. Verify correct
orifice is in seal air line.
 Visually check the main generator breaker compartment for cable terminations and
cleanliness. Breaker must be racked out during installation and pre-commissioning
checks.
 Check ratios and polarity of all Current and Potential Transformers and verify with all
electrical drawings. Check all site drawings. CT’s and PT’s are often wrong. Cross-
current CT shielding have a common ground. See Flick test.
 Ensure that the CT’s are properly terminated before shorting blocks for the CT’s are
removed.
 Ensure that all generator metering instrumentation shorts have been removed. Remove
shorting wires from console instruments.
 Check that the generator/switchgear have been meggered, inspected and certified for
startup. Verify the safety barrier/shutters function when the main circuit breaker is
removed. NOTE: follow manufacturer’s recommendations for meggering.
 Verify that space heaters are OK.
 Double check all wiring after all contractor hook-ups, and yellow-out drawings. Verify
that all jumpers are installed that should be installed. Ensure that the H.V. switchgear
protection has been calibrated and functionally checked on-site. It is preferred that
calibration be done by 3rd party or switchgear vendor.
 Verify the main circuit breaker trips when the switchgear protection relays trip.
Differential protection must use a “Fast Stop,” when the unit shutdowns occur (usually
on a common shutdown signal form the unit control console).
 Verify that phase rotation of generator phase is the same as utility/plant phase rotation to
tie phasing, ABC or CBA etc. Have a High Voltage contractor Hot Stick if possible.
 Check generator speed mode of operation, Droop or Isoch. Familiarize yourself with
both modes of operation and set speed Droop, if required. Set multiple units in Voltage
Droop. Check voltage ISOCH/DROOP.
 Verify exciter breaker closed (CB260).
 Verify LSM setup. Verify setup is same configuration (Delta or WYE) as switchgear,
ratios match hardware.
 For load sharing, verify wiring of K219-1A, especially if there is more than one unit. If
more than one unit, check wiring of cross current CT’s and PT’s for power factor/Kvar
control/ratios etc.
 For first Sync, close breaker in test position. Verify autosync calibration is correct.
 LSM load share lines installed correctly, especially shields. NOTE: New voltage
regulator - special resistors - might not match. Consult controls engineer.
 Ensure load gains are set correctly. Will vary per controlling devices.
 Verify generator lube system settings are correct. Set vents with doors closed on
enclosure. See generator vendor literature.
 Review Battery Chargers section. Lead or NiCad type. See SB 5.9/103A. Ensure
battery charger matches battery type. Initial NiCad charge requires special procedure.
 Verify and set purge time to reflect exhaust system. See SB 3.0/105D.
 VFD set-up on AC start motor.
 Woodward’s manual 0170B (Power Management) is very comprehensive.

Start System
Warning:
For Mars and Titan units review Hillard Pneumatic Starter Inspection Procedure.
Pneumatic Start System.
 Inspect electrical interconnect.
 Verify supply pressure.
 Inspect for correct trim in regulator.
 Blow down or clean by other method from gas pipes to skid edge. A temporary manifold
may be needed.
 Verify that no valves or blank-off plates are installed in the starter vent line. (See SB
22.0/100 for valves in starter vent lines.) Example: Mars starter case will fail if subjected
to full start gas pressure with blocked vent (closed valve). It has a 15 psi backpressure
limit.
 Verify that correct gas strainer has been installed in accordance with project start
drawing. Also see SB 2.1/106A for Centaurs and Taurus 60.
 Functional test system.
 Set cranking gas pressure during start.
 Ensure the internal reservoir is filled.
 Verify that the correct gas strainer is installed per project start drawing. See SB 2.1/106A
for Centaur and Taurus 60.
 All supply lines must be clean or unit will fail during first crank.
 Function test system.
 Set cranking gas pressure during start.
 See SB 22.0/100 for valves in starter vent lines.
 No rain hat permitted on natural gas vent line.

Example: Mars starter case will fail if subjected to full start gas pressure with
blocked vent (closed valve). It has a 15 psi back pressure limit.
Direct Drive AC (DDAC).
 Variable Frequency Drive (VFD) needs K-values. Reload default values, then enter K-
values.
 Ensure interconnect cable size is correct per drawing. Line Reactors are needed if over
900 feet. When armored cable is used, contact Solar for verification.
 Check that purge time requirements for heat recovery systems do not exceed starter duty
cycle.
First Engine Crank and Light-Off
Preparation
 Think Safety. Have an evacuation plan.

 Verify that all services are available (gas, air etc.)
 Verify that all block valves in all systems are in the correct position for starting.
 Think safety. Be prepared for the unexpected. Ensure manual fuel shutoff valve and start
gas shutoff valves are physically manned and operable. Ensure portable fire
extinguishers are available.
 Pre-lube package. If dry seal, verify buffer air is available and operational.
 Rotate turbine using the crank switch.
 Start turbine in automatic mode. Stop unit at first indication of T-5 temperature. This
verifies you can stop turbine.
 Detergent wash engine at this point before first light off, as necessary based on
preservation method, if applicable.
 If outside temperature is cold, may need methanol for water wash.
First Start
 Think Safety. Do not exceed a reasonable number of working hours.

 Do full automatic start to idle speed. Resolve all problems as they occur and check unit
for leaks or other problems.
 Check all systems for correct sequence during start.
 Check for unusual noises and vibration during start.
 If boost compressor has not been factory run, start-up at 10% increasing PT increments
for labyrinth seal break in. The seal break-in procedure must be followed.
On-Line/Operational Checks
 Oil Leaks.
 Gas Leaks.
 Air Leaks.
 Start Reliability Check.
 Speed Control.
 Surge Control System.
 Take Vibration Data.
 T-5 Topping Test, if possible.
SoLoNOx Field Commissioning Setup
 See TL 3.6/100C for Mars and SB 3.6/101,102,103 for various product lines.
 Similar setup is needed for Taurus 70's and may also be required for other engines.
Shutdown and Post-Operational Procedures
Shut unit down using Normal Stop.
 Verify correct sequencing of all systems during shutdown.

 For CS/MD, verify the recycle valve opens during the cool down stop.
 Listen for unusual noises during coast down.
 Verify correct post lube pump operation.
 Verify the Suction and Discharge valves close.
 Verify the Recycle valve is open, and the Vent valve opens when the case pressurization
time times out. (Double-check the timer setting.).
 Observe the time it takes to vent the unit to zero case pressure. Refer to the prints for
required blow down rates.
 KW control.
 Power factor control.
 Voltage regulation.
 Check fast stop operation.
 Correct any problems noted.
FSR Completion of Paperwork
 Follow parts return procedures in dossier or contact Commissioning. Do not leave any
excess or failed parts on site.
 Indicate first beneficial use date on “Acceptance.”
 Ask customer to sign the Final Customer Acceptance and to complete the Customer
Commissioning Survey in Part 1 of Commissioning Manual/Checklist.
 Create punch list in Part 2 Acceptance/Discrepancy Audit of Manual.
 Complete the ‘Start-up FSR ASL Evaluation.
 Scan or fax the Acceptance, Punch List, Customer Survey, and FSR ASL Evaluation to
Commissioning (858) 694-6801 (Attn: Expanded Services Commissioning).
 Complete as-installed drawings (red for deletions, green for additions) and software
including a memo stating why changes were made. Please send sheet 1 and changed
sheets only to Commissioning along with Parts 1 and 2 of the Commissioning Manual, if
not already scanned or faxed. Make a copy of the Manual for our customer, if desired,
and then send the entire Manual to your District Service Manager.
 If you have recommendations for improving/correcting this manual, please send or e-mail
to your Commissioning Project Support Engineer.
FSR Return Process
Solar Owned Parts Returned from New Build, Refurb, and Retrofit Commissioning
OBJECTIVE: Leave site in an orderly condition. Return parts that Solar can
redistribute for use or that require quality improvement. Scrap on site or in Mabank any
parts that could be used by Solar’s competitors or by customers for warranty claims
made in error.
RETURN PROCEDURE: Return Approval Not Necessary for Domestic Projects.

1) Commissioning Part Return Tag:
 Fill out and securely attach a Return Tag to each part.
 It’s very important to provide failure detail so Solar can keep record and correct
quality issues with suppliers.
 Include the original shipping documents if possible. This is helpful with claims on
damaged parts.
OR Obtain Return Order from Commissioning Specialist or Mabank
Commissioning Returns
 Noticeably write the return order on the package, adhere box label and ship.
2) Return parts to Mabank PROMPTLY: Before parts are damaged, package them
securely.
 Regular Domestic: Adhere FedEx label and contact Federal Express at 1-800-
463-3339 to arrange pickup, or simply contact Fed-Ex and reference account
#2607444.
 Heavy Weight Freight: When in doubt about parts over 3'x3'x3', or over 150lbs,
contact your contact your Mabank Traffic Specialist..
 For International Returns: Contact Commissioning Specialist or Project
Manager to determine if economical to return. Complete Commercial Invoice
provided. Include part numbers, quantities, prices and harmonized tariff codes,
referenced on the original shipping document.
 Additional information below….
REGULAR DOMESTIC SHIPMENTS:

If the weight equals or is less than 150 lbs and/or if girth is less than 130 inches, contact
FedEx at 1-800-463-3339. Use FedEx return label or bill Solar Acct # 2607444,
referencing the main account number 2686-9310-6 if needed.
[Formula for girth (longest dimension x 2) + (next longest dimension x 2) = less than
130 inches]
CONWAY HEAVY WEIGHT FREIGHT SERVICE:
If the weight is over 150 lbs, no one piece or palette exceeds 2200 lbs, and girth is less
than 300", Conway freight service at 1-800-532-7126. Bill Solar Account #:
SOLPDLTY000.
INTERNATIONAL RETURNS:
 If part is less than 250 lbs, request DHL Express.
 Use DHL inbound collect account 960-158-342.
 If DHL is not satisfactory, use the forwarder by whom Commissioning parts were
sent.
 If freight is above 250 lbs, please use (Solar’s) DHL Global Forwarding account
#: 7000SDFW.
SHIPPING PROBLEMS?: Direct problems by fax or Email containing weights and

dimensions to:
Solar Traffic Office

Mabank, Texas
Fax: 903-880-1408
Keith Kile: 903-880-1404, keithkile@solarturbines.com
Mike Hartnett: 903-880-1461, mikehartnett@solarturbines.com
Commissioning Returns Specialist:

Steve Droke: 903-880-1462, Droke_Steve@solarturbines.com
Return All Parts To:
SOLAR TURBINES
904 SOLAR TURBINES WAY, HWY 90
MABANK, TX 75147
903-880-1200
SCRAP PARTS: FSR is responsible for witnessing that parts are scrapped locally
when required. When in doubt, call the Commissioning Specialist or Project Manager
for guidance.
Shipping Requirements
(Note: GTC01)
Domestic Suppliers
Required Documentation
All shipments from U.S. Suppliers must be accompanied by a Packing
List, which includes the following information:
• Name and address of supplier
• Name and address of the buyer
• Date of issuance
• Packing List number
• Solar purchase order or contract number
• Country of origin (or manufacture) for each item
• Quantity and description of goods
• Unit of measure
• Gross weight of the goods
• Dimensions of the box as shipped
• Number of packages (i.e. box 1 of 3)
• Shipping marks and numbers
• Terms of delivery
Hazardous Material
No hazardous material will be returned to the Mabank facility.
Please contact the Commissioning Specialist or the Mabank Traffic Office
to get return instructions.
Identification of Country of Origin

Identification of U.S. country of origin is required to be noted on the
shipping documentation, preferably on the packing list. In order to
maintain proper country of origin for Solar Turbine export shipments, we
request to have the country of origin marked on all outside contains or
containers.
International Suppliers
Free Trade Agreements

The goods covered under this purchase order may be exported and may
be subject to a Free Trade Agreement or other trade initiatives. On an
annual basis, Solar Turbines will request verification of Free Trade
Agreement eligibility. Seller is obligated to furnish this information and to
notify Solar Turbines as changes in qualification or sourcing occur.
Acceptance or execution of a purchase order will affirm that no change
has occurred since the last notification.
Marking and Labeling

Every article of foreign origin and its container, when imported into the
United States, must be marked in English with country of origin. Marks
must be permanent, conspicuous and indelible. This requirement applies
to all imported parts including returns and repairs, unless the article is of
U.S. Origin. Each article must have the full English name of its country of
production or manufacture marked on the article. For further guidance,
refer to Title 19, section 134 of the U.S. Code of Federal Regulations
(19CFR 134).
Shipments originating in NAFTA countries please refer to Title 19, Part 102
for marking rules.
Commercial Invoice
The Commercial Invoice, which accompanies every shipment, must

contain the following information in English:
• Name and address of supplier
• Name and address of the buyer
• Date of issuance
• Invoice number
• Solar Purchase Order or contract number
• Country of origin (manufacture) for each item
• Quantity and description of goods
• Unit of Measure
• Unit price
• Total price
• Other agreed upon charges
• Total invoice amount stated in the currency of the contract
• Gross Weight of the goods (in pounds and kilograms)
• Dimensions of the box as shipped (in inches and centimeters)
• Number of packages
• Shipping marks and numbers
• Terms of delivery (International Chamber of Commerce – INCO)
• Harmonized Tariff Schedule code
• Terms of payment
• Signature of company representative completing the form
Additional Invoice Requirement:

The invoice accompanying the shipment of goods into the United States
must match the invoice presented to Solar Turbines for payment, including
the same invoice reference number, quantity, value and currency.
U.S. Origin Goods Returning to the U.S.

If value of invoice is over U.S. $10,000.00 and the goods are of U.S.
origin, a Foreign Shipper’s Declaration must be included with the shipping
documents.
Tooling and Other Assistance

Customs imposes duties on the full price paid or payable for all goods that
are imported into the United States. U.S. Customs considers assistance to
an unrelated supplier to be part of the price paid or payable. If Solar
Turbines purchases or supplies tooling, capital equipment, production
material, intellectual property or any other assistance to a non-U.S.
supplier at NO COST or at a
REDUCED COST, this information must be communicated by using the
Assist Reporting Form (number 4067) to the Import Specialists via the
t3_logistics_import@solarturbines.com account with a copy to the Solar
Buyer.
Wood Packing
All wood packing material must be treated and certified as per
International Standards for Phytosanitary Measures (ISPM) 15.
Hazardous Material
No hazardous material will be returned to the Mabank facility. Please
contact the commissioning specialist or Mabank traffic to get return
instructions.
ITAR (International Traffic in Arms Regulations)

Solar Turbines does not produce items that are specifically intended for or
have been designed, developed, configured, adapted or modified for
military applications. Our intention is to NOT purchase any item that
appears on the United States Munitions List (USML).
____________________________________________________________________________________
COMMISSIONING / RETROFIT PART RETURN TAGS

PART RETURN TAG Please fill out tag completely and attach it to
Project: SO #: each part being returned.
Pkg SN: Date:
FSR:
Ship to: Solar Turbines, Inc.
904 Solar Turbines Way, Hwy 90
Mabank TX 75147
Attn: Commissioning Returns
(903)880-4537
Part #:
Serial #:
Description:
Reason Failed Unused

Returned: Damaged Vendor Quality
DETAILS:
Do not mix Commissioning Returns with

Remanufactured parts.
Return of Parts to Owner
FROM: SOLAR TURBINES, INC.

New, Refurb, & Retrofit Commissioning Returns
SOLAR FSR
C/O
REF: PD#
PKG SN:
RETURN ORDER #
(If Available)
PD NAME
To:
SOLAR TURBINES INC.
ATTN: Commissioning Returns
904 Solar Turbines Way, Hwy 90
Mabank, TX 75147
Phone: 903-880-1462
BOX LABEL
Adhere this label to packages for returning parts.
COMMISSIONING CHECK LIST

PACKAGE MECHANICAL CHECKS
Check off when finished
1. Inventory Loose Ship Items.
2. Pre-Start Documentation and Procedures.
3. Equipment Installation.
 Enclosure
 Inlet
 Exhaust
 Ancillary
 Oil Coolers
4. Oil System Requirements.
5. Lube Oil System Flush.
6. Alignment Checks.
PRE POWER-UP ELECTRICAL CHECKS
1. Electrical System Preliminary.
2. Interconnect Wiring Checks.
3. Ground System Checks.

4. MCC Checks.
5. Battery Charger Checkouts 24VDC/120VDC.
6. Control Console Preliminary Checks.

WHEN DC POWER IS APPLIED
1. Powering up Control Console.
2. Check Displays Local/Remote.
3. Run All Motors Electrically.
4. Lube Oil Sequence Checks.
5. Fire System Checkouts.
6. Gas System Checkouts.
7. Check All Fast Stop Push Buttons.
8. Generator Safety Checks.
9. Switch Gear Checks.
OPERATIONAL CHECKS
1. Engine First Crank/Detergent Wash.
2. Engine First Light-off.
3. Post Operational Checks.
4. Voltage Build.
5. Record any open Items.

COMMISSIONING CHECK INSTRUMENT SHEET TRANSMITTERS
RANGE
TRANSMITTER PLC
DESCRIPTION PASS DATE INITIAL
N0. ADDRESS MINIMUM MAXIMUM
DESIRED DESIRED
ACTUAL ACTUAL
Comments:
COMMISSIONING CHECK INSTRUMENT SHEET TRANSMITTERS
RANGE
TRANSMITTER PLC
DESCRIPTION PASS DATE INITIAL
N0. ADDRESS MINIMUM MAXIMUM
DESIRED DESIRED
ACTUAL ACTUAL
Comments:
COMMISSIONING CHECK INSTRUMENT SHEET SOLENOIDS.
PLC
SOLENOID DESCRIPTION ENERZISE PASS DATE INITIAL
ADDRESS
Comments:
COMMISSIONING CHECK INSTRUMENT SHEET SOLENOILDS
PLC
SOLENOID DESCRIPTION ENERZISE PASS DATE INITIAL
ADDRESS
Comments:
COMMISSIONING CHECK INSTRUMENT SHEET PRESSURE SWITCHES
SETPOINT SETPOINT SETPOINT SETPOINT

SWITCH PLC
DESCRIPTION INCREASING DECREASING INCREASING DECREASING PASS DATE INITIAL
N0. ADDRESS
REQUIRED REQUIRED ACTUAL ACTUAL
Comments:
COMMISSIONING CHECK INSTRUMENT SHEET PRESSURE SWITCHES
SETPOINT SETPOINT SETPOINT SETPOINT

SWITCH PLC
DESCRIPTION INCREASING DECREASING INCREASING DECREASING PASS DATE INITIAL
N0. ADDRESS
REQUIRED REQUIRED ACTUAL ACTUAL
Comments:
COMMISSIONING CHECK INSTRUMENT SHEET ACTUATORS
PLC
ACTUATOR DESCRIPTION ENERZISE PASS DATE INITIAL
ADDRESS
Comments:
COMMISSIONING CHECK INSTRUMENT SHEET ACTUATORS
PLC
ACTUATOR DESCRIPTION ENERZISE PASS DATE INITIAL
ADDRESS
Comments:

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Solar Turbomachinery

Controls Retrofit and Expanded Services

Caterpillar: Confidential Green

The contents of this technical publication are proprietary data of Solar

To: Solar Turbines Field Service Reps.

1. After you have completed this Manual, please distribute it as follows:

3. Give a copy of the manual to the customer, if desired.

COMMISSIONING CHECKLIST AND CUSTOMER ACCEPTANCE

CUSTOMER ENGINEER: CUSTOMER SITE SUPERINTENDENT:

MILLWRIGHT COMPANY: SITE FOREMAN / PHONE:

PIPEFITTER COMPANY: SITE FOREMAN / PHONE:

WELDER COMPANY: SITE FOREMAN / PHONE:

COMMISSIONING CHECKLIST AND CUSTOMER ACCEPTANCE

ELECTRICAN HIGH VOLTAGE CO: SITE FOREMAN / PHONE:

ELECTRICAN LOW VOLTAGE CO: SITE FOREMAN / PHONE:

INSTRUMENT & TUBING CO: SITE FOREMAN / PHONE:

SOLAR – SAN DIEGO CONTACTS

SPECIAL INSTRUCTIONS OR OTHER RELEVANT INFORMATION

EQUIPMENT COMMISSIONING CHECKLIST

_____________________________________________________ _______________________ _______________

CUSTOMER ACCEPTANCE DATE: _______________ SHIPMENT DATE: ________________________

EXTENDED WARRANTY EXPIRATION DATE:_____________________________________________________________

END USER: _______________________________________________ DATE:____________________________________

CUSTOMER COMMISSIONING SURVEY

Please rate each of the following areas, as applicable, on a scale

MODEL: __________________________________________________ S/N:_________________________________

2. "AS SHIPPED" DRAWINGS: N/A 1 2 3 4 5

TURBINE S/N: ______________________________________________ S/N:_________________________________

3. CONDITION OF “PRODUCT”: N/A 1 2 3 4 5

4. PACKING LIST: N/A 1 2 3 4 5

5. COMPLETENESS OF “PRODUCT”: N/A 1 2 3 4 5

6. ANCILLARY COMPONENTS: N/A 1 2 3 4 5

7. COMMUNICATIONS WITH SOLAR: N/A 1 2 3 4 5

8. EXPERTISE OF SOLAR’S SITE PERSONNEL: N/A 1 2 3 4 5

9. MAINTENANCE MANUAL AND PARTS LIST: N/A 1 2 3 4 5

Address/ phone number: _________________________________________________

Start-up FSR Shipping Evaluation Form

Project Name: _______________________ PD#: _____________________

1. Overall Shipment Accuracy N/A 1 2 3 4 5

2. Kit(s) Accuracy N/A 1 2 3 4 5

3. Shim Kit(s) Accuracy N/A 1 2 3 4 5

4. Interconnect Hardware Accuracy N/A 1 2 3 4 5

5. Ancillary Accuracy N/A 1 2 3 4 5

6. Quality of Shipment Packing N/A 1 2 3 4 5

All major discrepancies encountered during commissioning and resolutions or corrective

Discrepancy Audit Sheet (Page 12)

Discrepancy / Resolution Report – General (Pages 13 to 17)

Discrepancy / Resolution Report – Electrical Conduit Sealing (P18-19)

STANDARDS AND CODES:

CUSTOMER: _____________________ SITE:_____________________

ITEM DATE SOLAR REP.

DATE:__________________ ITEM NO.___________________________

EVERYTHING STATED IN RESOLUTION BOX HAS BEEN COMPLETD AND ACCEPTED.

DATE:__________________ ITEM NO.__________________________

EVERYTHING STATED IN RESOLUTION BOX HAS BEEN COMPLETD AND ACCEPTED.

DATE:__________________ ITEM NO.__________________________

EVERYTHING STATED IN RESOLUTION BOX HAS BEEN COMPLETD AND ACCEPTED.

DATE:__________________ ITEM NO.___________________________

EVERYTHING STATED IN RESOLUTION BOX HAS BEEN COMPLETD AND ACCEPTED.

EVERYTHING STATED IN RESOLUTION BOX HAS BEEN COMPLETD AND ACCEPTED.

DATE:__________________ ITEM NO.______________________

SAFETY COMPLIANCE: Engine Crank and Light-off

CUSTOMER HAS DECLINED TO HAVE ELECTRICAL CONDUITS SEALED IN

DATE:__________________ ITEM NO.______________________

_________________________________________ _ _____

CUSTOMER ACCEPTANCE DATE: _ SHIPMENT DATE: __________

END USER: ___________ DATE:

MODEL: __________________ S/N:_

TURBINE S/N: ______________ S/N:_

Project Name: ___ PD#: _

CUSTOMER: _ SITE:_

DATE: ITEM NO._________

DATE: ITEM NO.________

DATE: ITEM NO.________

DATE: ITEM NO._________

DATE: ITEM NO.____

DATE: ITEM NO.____