Vol 1

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Installation and Commissioning Services

Manual (ICS Manuals)
Volume 1 Trent - Mechanical and Controls/Electrical Installation Information
Revision Level: 0
Customer: Kenko Bolivia
M.A606.01
GED00240683
Export Controlled
This document contain technical data whose export is restricted by the
Export Administration Act of 1979, as amended, (Title 50, U.S.C., App.
2401, Et Seq.). and is controlled by the Export Administration Regula-
tions (15 CFR parts 730-774) under ECCN EAR99. Diversion contrary
to US export law is prohibited.
Liability Disclaimer
This information is given in good faith, based on the latest information
available. No warranty or other representation is given concerning such
information, which must not be taken as establishing any contractual or
other commitement by the company or any of its subsidiaries or associ-
ated companies.
Proprietary Rights Legend

This technical data and the information embodied herein is the property
of and proprietary to Rolls-Royce plc., and shall not, without prior written
permission of Rolls-Royce pIc. be disclosed in whole or in part to third
parties. This legend shall be included on any reproduction of this data in
whole or in part.
ro
Manual Updates
For the latest updates to all technical documentation please register at www.energymanager-online.com
Rolls-Royce distributes updates for manuals, service bulletins, turbo bulletins and service information let-
ters to the nominated address of the manual holder. These documents can contain information regarding
the safe operation of the equipment and it is in the interests of both the operator/owner and Rolls-Royce to
ensure that these documents are received and acted on as necessary. Rolls-Royce may not be aware of
changes in the operator's/owner's organisation or changes in ownership of equipment. It is the responsibil-
ity of the equipment operator/owner to ensure that any changes in manual holder and/or address, or any
changes in equipment ownership are reported to Rolls-Royce. Rolls-Royce will not be held responsible for
any losses, damages or other consequences which may arise out of the operator's/owner's lack of receipt
of the documentation and updates referred to above, where such changes have not been advised to Rolls-
Royce in writing.
Table of contents ro
Export Controlled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Liability Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Proprietary Rights Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation and Commissioning Services Manual (ICS Manuals). . . . . . . . . . . . . . . . . . . . 1
Manual Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Chapter 1 - Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operations Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
America’s Region Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Asia Pacific Region Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Middle East Region Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2 - Pre-installation Activities
Section I - - Mechanical Pre-installation Activities

Activity 1 - Receiving the Gas Turbine/Acoustic Enclosure Skid . . . . . . . . . . . . . . . . . . . 15
Activity 2 - Receiving the Trent Gas Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Activity 3 - Receiving the A/C Generator Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Activity 4 - Receiving the Combustion Air Inlet Housing / Support Structure . . . . . . . . . 27
Activity 5 - Receiving Gas Turbine Enclosure Acoustic Roof Sections & Door Railing. . 31
Activity 6 - Receiving Gas Turbine Ventilation System (Inlet and Outlet) . . . . . . . . . . . . 35
Activity 7 - Receiving Bleed (BOV) Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Activity 8 - Receiving Exhaust Transition Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Activity 9 - Receiving Gas Turbine / Generator Coupling . . . . . . . . . . . . . . . . . . . . . . . . 47
Activity 10 - Receiving CO2 Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Activity 11 - Receiving Gas Turbine Mechanical Handling Skid. . . . . . . . . . . . . . . . . . . . 55
Activity 12 - Receiving Gas Turbine Lube Oil Demister . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Activity 13 - Receiving A/C Generator Lube Oil Console. . . . . . . . . . . . . . . . . . . . . . . . . 63
Activity 14 - Receiving Shipped Loose Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Activity 15 - Receiving Water Wash Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Section II Introduction: Electrical Pre-commissioning Activities . . . . . . . . . . . . . . . . . . . . . 77
Activity 16 - Receive and Install Unit Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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Activity 17 - Receive and Install Electric Starter Controller Panel . . . . . . . . . . . . . . . . . . . 83

Activity 18 - Receive and Inspect Main Control Room HMI (FT-210) . . . . . . . . . . . . . . . . 87
Activity 19 - Receive and Inspect Air Inlet Filter House Control Panel. . . . . . . . . . . . . . . 89
Activity 20 - Provide Temporary Power to All Motors, Generator, and Panels Anti-
condensation / Space Heaters when on Storage . . . . . . . . . . . . . . . . . . . . . . 91
Chapter 3 - Installation Activities

Chapter Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Activity 21 - Check Foundation Blocks and Datum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Activity 22 - Position the A/C Generator Skid Over the Hold-down Bolts . . . . . . . . . . . . . 101
Activity 23 - Position the Gas Turbine Skid Over the Hold-down Bolts . . . . . . . . . . . . . . . 103
Activity 24 - Leveling the Baseplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Activity 25 - Install the GT Exhaust Transition Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Activity 26 - Erect and Install the Gas Turbine Roof Sections (4) . . . . . . . . . . . . . . . . . . . 109
Activity 27 - Install the AC Generator Air Cooler Module . . . . . . . . . . . . . . . . . . . . . . . . . 111
Activity 28 - Alignment Gas Turbine to A/C Generator (Pre-Grout). . . . . . . . . . . . . . . . . . 113
Activity 29 - Grout the Gas Turbine and A/C Generator Skids . . . . . . . . . . . . . . . . . . . . . 117
Activity 30 - Position the Gas Turbine Mechanical Handling Skid and Grout . . . . . . . . . . 119
Activity 31 - Load Test All Package Supplied Lifting Equipment . . . . . . . . . . . . . . . . . . . . 121
Activity 32 - Position and Install A/C Generator Lube Oil Skid . . . . . . . . . . . . . . . . . . . . . 123
Activity 33 - Install the A/C Generator Line and Neutral Cubicles . . . . . . . . . . . . . . . . . . . 125
Activity 34 - Erect and Install GT Bleed Ductwork (BOV). . . . . . . . . . . . . . . . . . . . . . . . . 127
Activity 35 - Erect and Install the Gas Turbine Ventilation System (Inlet & Outlet) . . . . . . 129
Activity 36 - Install the Air Filter House. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Activity 37 - Erect and Install Air Filter House Structure . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Activity 38 - Position and Install CO2 Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Activity 39 - Install Flexible Drive Shaft Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Activity 40 - Install Gas Turbine in Berth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Activity 41 - Package Gas Turbine Alignment - Final Check. . . . . . . . . . . . . . . . . . . . . . . 149
Activity 42 - Gas Turbine Interface Connections / Air, Water, Fuel, Lube & Hydraulic Oil. 151
Activity 43 - Installation of the Enclosure Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Activity 44 - Erect and Install Gas Turbine Lube Oil Demister . . . . . . . . . . . . . . . . . . . . . 155
Activity 45 - Installation of Cross Site Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Activity 46 - Unit Control Panel Electrical, Control and Communication Cables Interconnect
171
Activity 47 - Generator Control Protection Panel (GCPP) Electrical, Control and
Communication Cables Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Activity 48 - VFD for Water Injection (3), Inlet Spray Intercooler (3), Water Flush (1)
Communication / Electrical Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Activity 49 - Engine Starter Controller Panel Electrical, Control and Communication Cables
Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Activity 50 - Motor Control Center Communication and Electrical Interconnect . . . . . . . . 195
Activity 51 - Control Panel Bonding, Safety and Instrument (Signal) Ground . . . . . . . . . . 199
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Activity 52 - Fire and Gas System Interconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Activity 53 - CO2 Cabinet Bonding and Equipment / F&G Devices Ground . . . . . . . . . . 209
Activity 54 - Gas Turbine Ventilation Fan Motor (3) Electrical Interconnect . . . . . . . . . . 213
Activity 55 - GT Enclosure Ventilation Fire Damper (2) Control Interconnect . . . . . . . . . 217
Activity 56 - GT Enclosure Installation of Electrical Ship Loose Items and Interconnect . 221
Activity 57 - Engine Starter Electrical / Control Interconnect . . . . . . . . . . . . . . . . . . . . . . 225
Activity 58 - GT Instrument / Control Interconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Activity 59 - Gas Fuel Metering Valves Controller Interconnect. . . . . . . . . . . . . . . . . . . . 253
Activity 60 - Gas Turbine Hydraulic Oil Pump Motor (2) Electrical Interconnect . . . . . . . 259
Activity 61 - GT Lube Oil Reservoir Heater Electrical Interconnect . . . . . . . . . . . . . . . . . 263
Activity 62 - ASC Secondary Air Fan Electrical Interconnect. . . . . . . . . . . . . . . . . . . . . . 267
Activity 63 - Air Filter Inlet House / Pulse Air Control Panel Electrical Interconnect . . . . 271
Activity 64 - Gas Turbine / Generator and Enclosure Bonding and Grounding . . . . . . . 277
Activity 65 - Generator Space Heater Temporary Power . . . . . . . . . . . . . . . . . . . . . . . . 279
Activity 66 - Generator Exciter End Enclosure Electrical Interconnect . . . . . . . . . . . . . . 281
Activity 67 - Generator Monitoring Panel Electrical Interconnect. . . . . . . . . . . . . . . . . . . 287
Activity 68 - Generator HV Electrical Interconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Activity 69 - Generator Instrument / Control Cable Interconnect . . . . . . . . . . . . . . . . . . . 295
Activity 70 - Generator Current and Potential Transformer Electrical Interconnect . . . . . 301
Activity 71 - Generator Lube Oil Auxiliary Pump Electrical Interconnect . . . . . . . . . . . . . 305
Activity 72 - Generator Jacking Oil Pump Electrical Interconnect . . . . . . . . . . . . . . . . . . 309
Activity 73 - Generator Emergency Lube Oil Pump ( DC ) Electrical Interconnect . . . . . 313
Activity 74 - Generator Lube Oil Dimister Motor Electrical Interconnect . . . . . . . . . . . . . 317
Activity 75 - Generator Lube Oil Heater Electrical Interconnect . . . . . . . . . . . . . . . . . . . 321
Activity 76 - Generator Lube Oil Skid Instrument / Control Interconnect . . . . . . . . . . . . . 325
Activity 77 - Set up of HMI (FT210) Servers and communications . . . . . . . . . . . . . . . . . 331
Activity 78 - Generator Insulation Resistance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Chapter 4 - Electrical activities

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Chapter 5 - Safety method statement

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Electricity - above 240v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Electricity - up to 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Electricity - ignition system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Synthetic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Motor rotation checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Pressure testing with nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Working with restricted access / obstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
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Fire and gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Preparation for engine crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Initial crank of the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Washing the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Hazardous atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Test schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Chapter 6 - Risk assessment

Assessment with existing control measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Assessment of risk reduction actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Guidance on completion of risk assessment form. . . . . . . . . . . . . . . . . . . . . . . . . . 367
Chapter 7 - Engineering standards

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Engineering standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Gas turbine engineering requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Gas turbine engineering specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Miscellaneous documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Chapter 8 - Forms
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Chapter 9 - Drawings
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Project drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Chapter 10 - Spare parts list
Chapter 11 - Questionnaire
Installation and commissioning manuals questionnaire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Questionnaire on spare parts provided for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 391
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Chapter 1 Introduction
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Introduction
This Installation and Commissioning Services (ICS) Manual is written to assist personnel involved in the instal-
lation, pre-commissioning and commissioning of the Trent Package.
The information given is in the form of "Method Statements" which are intended to provide a permanent record
of the completeness of the installation. Each section is broken down into sub-sections that have columns, which
must be signed, witnessed and dated by previously authorized personnel.
At the end of the manual, there is a "Statement of Acceptance", which incorporates an area to record "Punch
List Items" which will constitute exceptions to the "Statement of Acceptance". This statement must be completed
and signed by the Rolls-Royce representative and the Customer Witness when the commissioning has been
completed, where upon the warranty obligations of Rolls-Royce shall commence.
This manual has been compiled in a logical manner but it is the prerogative of the site team to alter the sequence
of events to suite the site conditions.
As each section is completed the authorized personnel are to include under Comments or Drawing Reference.
the Reference Drawings used, including the Revision Number.
Any errors or omissions in this manual are to be corrected by the Installation and Commissioning Manager (ICM)
or the Rolls-Royce site representative and highlighted in the copy returned to Mt. Vernon. Likewise any site
changes are to be included in this manual and marked up on the appropriate drawing, which is to be sent to Mt.
Vernon for the attention of the Project Logistics Leader (PLL).
Note
Once the activities have been completed and the Statement of Acceptance has been signed off
this manual is considered completed. It will no longer be maintained or updated.
The completed copy of this manual allocated to the Rolls-Royce Energy Systems Inc. (RRESI) ICM must be
returned to RRESI Mt. Vernon for inclusion in the archive.
Return address:
Rolls-Royce Energy Systems Inc.
105 North Sandusky St.
Mount Vernon, Ohio 43050
F.A.O. ICS Methods Group
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Important Notice
This manual contains confidential and proprietary information of Rolls-Royce plc. It is submitted to you for the
limited purpose of providing information to facilitate the installation and commissioning of the products supplied
by the said company. By receiving this document, you agree not to use such confidential information for any
purpose other than the limited purpose stated herein and further agree not to disclose such information to others
except in accordance with the limited purpose stated herein.
Safety
The following items should be noted prior to operating or servicing the equipment:
• Undertaking any work envisaged by this document may either directly or indirectly create risks to
(1) the safety and health of the person undertaking the work or (2) the engine and/or its compo-
nents whilst the work is being undertaken.
• It is the responsibility of the user to ensure that appropriate controls and precautions are identified
and applied in relation to the work envisaged by this document in accordance with the relevant
statutory, legal and industry requirements to protect the health and safety of the persons undertak-
ing the work.
• It is also the user's responsibility to ensure that appropriate controls and precautions are identified
and applied in relation to work envisaged by this document to protect against risks to the engine
and/or its components whilst the work is being undertaken.
• Neither this document, nor its use, in any way absolves the user from their responsibility to ensure
that the controls and precautions referred to above are implemented.
• If, whilst undertaking any work envisaged by this document, you become aware of any Rolls-
Royce product design related feature which could create risk to a person undertaking work or to
the engine and/or its components please contact your regional technical support department
immediately.
• It is the user's responsibility to make all relevant hazard identifications and risk assessments of all
the activities associated with the use of this document.
• It is the user's responsibility to design and implement safe systems of work and to supply safe
equipment (including, without limitation, safety equipment) and training (including, without limita-
tion, health and safety training) to anyone using this document to work on products to which is
relates.
• A user without the relevant experience of working in accordance with this document or with prod-
ucts, or similar products, to which it relates should seek appropriate advice to enable them to iden-
tify the appropriate health and safety controls and precautions and controls and precautions to
protect against risks to the engine and/or its components whilst work is being undertaken. Techni-
cal assistance can be sought from Rolls-Royce and will be subject to Rolls-Royce's terms and
conditions.
• Do not enter the plenum chamber while the Gas Generator (GG) is operating. Keep the plenum
chamber door access door closed and locked, except during servicing.
! Warning
While the GG is running, in-rushing air can force a person into the GG inlet causing injury or
death.
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• Do not enter the gas turbine enclosure while the GG is operating above idling speed. The GG pro-
duces noise levels capable of causing hearing loss, cause unsteadiness, or the inability to stand or
walk without losing balance. All personnel must use approved ear protection when inside the
machinery room while the equipment is operating.
! Warning
Entering or remaining in the enclosure during a release from a CO2 smothering system causes
suffocation and death. Fully ventilate the enclosure after a CO2 release and prior to entering the
enclosure.
• Do not enter areas protected by CO2 smothering system, unless the fire protection system has
been isolated and CO2 release is impossible while personnel is inside.
• Due to high operating temperatures of the GG and Power Turbine (PT), no work or inspection shall
be performed, for a minimum of 90 minutes, once the equipment stops operating.
• Do not work on the ignition system when it is energized.
! Warning
The ignition system is a high-energy system and could cause a fatal injury. When working on
the system, ground the igniter plug hot leads at the earliest opportunity.
• Do not remove pressure gauges or switches until the lines in which they are mounted have been
de-pressurized.
• Do not allow GG lubricating oil to remain in contact with your skin for long periods of time.
! Caution
GG Lubricating oil can cause toxic poisoning due to absorption through the skin.
• Do not handle extremely hot items with unprotected hands since burns may result. Allow the items
to cool to the ambient temperature prior to performing work.
• Due to the heavy weights of some of the equipment, extreme care must be exercised during
assembly and maintenance procedures.
! Caution
The fire retention dampers are an automated system. When working on dampers, always
ensure they are isolated from all activation sources.
• Isolate dampers from electrical power
• Isolate pneumatic supply
• Isolate CO2 supply
• Insert a physical stop in the louvre blades
Training
Introductory and continuing education is required to reduce downtime, increase fuel savings, reduce liability risk

Introduction ro
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and cost, and extend the equipment’s life cycle. Rolls-Royce supports dedicated customer training facilities
around the world staffed with full-time, field experienced technical training instructors providing a practical and
theoretical understanding of the equipment purchased.
7
Introduction ro
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Professional Instructors, who know equipment design and application, are able to convey how and why the
equipment works the way it does, and, how it is correctly and safely operated and maintained to optimize effi-
ciency and salvage cost during production. Our dedicated training facilities are located:
• Americas
105 North Sandusky Street
Mount Vernon, Ohio 43050
U.S.A.
Telephone: (740) 393-8888
Fax: (740) 393-8336
Training Services Telephone: (740) 393-8853
• Europe
Ansty, Conventry CV7 9JR
England
Telephone 44-2476624000
Fax 44-2476624666
Training Services Telephone: 44-2476623483
• Far East
16 International Business Park
Unit 03-09
Singapore 609929
Telephone: 65-8990092
Fax: 65-8624495
Note
Please remember to use the international dialling codes.
Qualifications
Maintenance Personnel
Equipment maintenance must be performed by mechanical and electrical technicians who are adequately
trained and qualified in the maintenance of this type of machinery. For personnel and plant safety, comply with
all relevant safety instructions, cautions, and warnings within the equipment manuals.
Installation Personnel
Equipment installation must be performed by personnel who are trained, qualified, and certified for the mechan-
ical and electrical installation of this equipment. Personnel must be certified and trained to applicable codes and
standards, local and international where applicable, in order to ensure a contract compliant installation. If equip-
ment is not installed by qualified personnel then there is a risk of equipment failure, non-compliance, and safety
concerns. For personnel and plant safety, comply with all relevant safety instructions, cautions, and warnings
within the equipment manuals.

Introduction ro
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Operations Personnel
Equipment operation must be performed by personnel who are adequately trained and qualified in the operation
of this type of machinery. Personnel operating this equipment must be familiar with the equipment manuals prior
to performing work. For personnel and plant safety, comply with all relevant safety instructions, cautions, and
warnings within the equipment manuals.
Technical Support
If you have any comments or suggestions regarding the equipment, please call or fax
them to Rolls-Royce Energy Systems, Inc. Technical Support at (please remember to
use the international dialling codes):
United Kingdom
Customer Service Business
Rolls-Royce Power Engineering plc
Ansty COVENTRY CV7 9JR
Tel: (0) 24 7662 3483 Fax: (0) 24 7662 4017
America’s Region Operators
Canada
Customer Service Business-Energy
Rolls-Royce (Canada) Ltd.
9500 Cote de Liesse
Lachine CANADA H8T 1A2
Tel: 514 636 0964 Fax: 514 633 7919
United States
Technical Support Department
8303 McHard Road
Houston TX 77053 USA
Tel: 281 436 6700 Fax: 208 762 9388
Asia Pacific Region Operators

Rolls-Royce Pte. Limited
16, International Business Park
Unit 03-09
Singapore 609929
Tel: 6899 0092 Fax: 6862 4495
9
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Middle East Region Operators

Fotouh Al Khair Centre
Tower 3, Floor 0
PO Box 44183
Abu Dhabi UAE
Tel: 971 2 6311959 Fax: 971 2 6351242

Chapter 2 Pre-installation
Activities
11
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Section I - Mechanical Pre-
installation
Activities
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INSTALLATION AND COMMISSIONING ACTIVITY SHEET
KENKO BOLIVIA - M.A606.01
Completed Witnessed
Work Description By By Date
Activity 1 - Receiving the Gas Turbine/

Acoustic Enclosure Skid
Reference Documents
GED00221287 - General Arrangement
GED00221288 - Foundation and Loading Plan
GED00221289 - Shipping Outline
GED00221290 - Mechanical Handling - Trent 60 WLE
GEM 0143 - Interior Treatment with Volatile Corrosion
Inhibitor (VCI) Crystals for Rust Prevention
GEM 0144 - Receiving and Storage Instructions for Rolls-
Royce Rotating Equipment at Customer Site
Main Module Weights
Please refer to the Rolls-Royce drawings listed above for
the weights of the major components. For more
information, refer to chapter “Engineering Standards,
Forms, and Drawings.
Offloading
1) After removing the packing cases from the transport
inspect all shipped material for signs of shipping damage.
Note: Log all damages and shortages and notify Rolls-
Royce And all applicable parties. It is the Customer's
responsibility to off load and store the equipment, to
maintain an inventory, as well as warehouse records and
shelf locations.
Comments
Signatures / Date
Print Name Signature
Customer
Rolls-Royce
15
Completed Witnessed
Receiving and Inspecting

1) Within 14 days of the equipment arriving at site, a full
inventory of the contents of all the boxes must be held.
This must be carried out with a representative of the
Customer present.
Note: If discrepancies / shortages are observed during the
inventory, these are to be reported back to the Project
Team in Mt. Vernon. These will be investigated by the
Project Team in Mt. Vernon and will arrange for
replacements as required.
2) It is the customer's responsibility to make provision for
the storage of the parts in a secure location that provides
protection from the elements, that is free from sudden
temperature changes that may cause moisture
condensation, free from dust, dirt and other foreign
materials. It must also be free from insect and vermin
invasion. It is also the customers responsibility to maintain
an inventory, including shelf locations, for all the stored
parts.
Add protective compounds if deterioration is observed as
outlined in Rolls-Royce Engineering Standards GEM 0143
and GEM 0144. For more information, refer to chapter
"Engineering Standards, Forms, and Drawings."
Note: Periodic inspections are to take place on the stored
equipment to ensure that this remains in good condition.
Refer to the Manufactures or Vendors manuals and
drawings for periodic inspection requirements. Record and
document all periodic inspections.
Comments
Signatures / Date
Customer
Rolls-Royce
16
Completed Witnessed
Note: Once the inventory has taken place, any subsequent

missing parts will be deemed to have been lost at site, and
the Project Manager will arrange to charge the customer
for replacements.
3) Open each box and check that the contents are as per
the Packing Lists.
4) Ensure that each part is suitably identified with; the part
number, drawing number, item number and the unit serial
number.
5) Confirm that all boxes shown on packing lists have
arrived on site.
6) Collect all commonly identified boxes in the same area.
7) Unpack loose items and check off against pack lists.
8) Make sure that each item is suitably identified, i.e.
drawing number, item number, and unit serial number.
9) List and report shortages to the Rolls-Royce Field
Service Representative.
10) Make an itemized list of the material using the unit
number and store these items by unit number.
11) Store the equipment in an area that provides the
following minimum requirements:
a) A dry covered storage area.
b) No sudden temperature changes that could cause
moisture condensation.
c) Easy access for inspection and/or service.
d) Free from dirt, dust and foreign material.
Comments
Signatures / Date
Customer
Rolls-Royce
17
Completed Witnessed
e) Free from vermin or insect invasion.

12) Photograph all damage. If necessary, return damaged
material to Rolls-Royce.
Comments
Signatures / Date
Customer
Rolls-Royce
18
Completed Witnessed
Activity 2 - Receiving the Trent Gas

Turbine
Reference Documents
Generator vendor literature
Main Module Weights
information, refer to chapter "Engineering Standards,
Forms, and Drawings."
Note: Rolls-Royce provides two (2) lifting beams for GT
installation, LOT 94127 (Gas Turbine Only Lifter) and LOT
94130 (Gas Turbine and Stand Lifter), engine stand and
environmental housing, which remain the property of Rolls-
Royce.
The gas turbine (GT) is supplied in an Environmental
Protection Cover (EPC) which includes the GT and the GT
cradle. The GT must remain inside this cover until
immediately prior to its installation into the unit and until
that time must only be lifted using the lifting points clearly
marked on the stand.
Comments
Signatures / Date
Customer
Rolls-Royce
19
Completed Witnessed
Offloading
After removing the packing cases from the transport
Royce and all applicable parties. It is the Customer's
shelf locations.
Customer present.
parts. Add protective compounds if deterioration is
Comments
Signatures / Date
Customer
Rolls-Royce
20
Completed Witnessed
observed as outlined in Rolls-Royce Engineering

Standards GEM 0143 and GEM 0144. For more
for replacements.
the Packing Lists.
4) Ensure that each part is suitably identified with; the
part number, drawing number, item number and the unit
serial number.
arrived on site.
6) Collect all commonly identified boxes in the same
area.
8) Make sure that each item is suitably identified,
i.e.drawing number, item number, and unit serial number.
Comments
Signatures / Date
Customer
Rolls-Royce
21
Completed Witnessed
Safety Note: Store the equipment so as not to provide
a hazard to other activities taking place on site
Safety Note: The EPC that the GT is supplied in will not
protect the GT from damage from falling objects or
other forms of impact.
Comments
Signatures / Date
Customer
Rolls-Royce
22
Completed Witnessed
Activity 3 - Receiving the A/C Generator

Skid
Reference Documents
GED00230718 - Generator General Arrangement
Refer to the Siemens vendor documentation for additional
receiving and unpacking instructions.
Note: The Siemens A/C generator shipment consists of the
main generator skid, air cooler assembly, line cubicle,
neutral cubicle, support structure, and accessory box of
material.
Main Module Weights
Offloading
Comments
Signatures / Date
Customer
Rolls-Royce
23
Completed Witnessed

shelf locations.
Customer present.
Team in Mt.Vernon. These will be investigated by the
Project Team in Mt.Vernon and will arrange for
Comments
Signatures / Date
Customer
Rolls-Royce
24
Completed Witnessed

Note: Note: Once the inventory has taken place, any
subsequent missing parts will be deemed to have been lost
at site, and the Project Manager will arrange to charge the
customer for replacements.
the Packing Lists.
number.
arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
25
Completed Witnessed

Safety Note: Store the equipment so as not to provide
a hazard to others activities taking place on site.
Safety Note: The EPC that the GT is supplied in will not
protect the GT for damage from falling objects or other
forms of impact.
Comments
Signatures / Date
Customer
Rolls-Royce
26
Completed Witnessed
Activity 4 - Receiving the Combustion

Air Inlet Housing / Support Structure
Reference Documents
GED00207857 - Trent 60 WLE Combustion Air System
Diagram
Refer to the AAF vendor documentation for additional
Note: The air intake filter house, Secondary air fan, support
structure, and access platforms will be shipped as several
bulk modules that are required to complete one (1) unit.
The air filter elements will be shipped in a sea container.
Main Module Weights
Offloading
Comments
Signatures / Date
Customer
Rolls-Royce
27
Completed Witnessed

shelf locations.
Customer present.
Note: Note: If discrepancies / shortages are observed
during the inventory, these are to be reported back to the
Project Team in Mt.Vernon. These will be investigated by
the Project Team in Mt.Vernon and will arrange for
Comments
Signatures / Date
Customer
Rolls-Royce
28
Completed Witnessed

for replacements.
the Packing Lists.
number.
arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
29
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
30
Completed Witnessed
Activity 5 - Receiving Gas Turbine

Enclosure Acoustic Roof Sections &
Door Railing
Reference Documents
GED00194621 - Enclosure - GT Acoustics (Starboard Side
Wall #2)
GED00194626 - Enclosure - GT Acoustics (Roof Assembly
#1)
#2)
#3)
#4)
GED00194630 - Enclosure - GT Acoustics (Door Rail
Assembly)
Refer to the AAF vendor documentation foradditional
Comments
Signatures / Date
Customer
Rolls-Royce
31
Completed Witnessed
Note: The Gas Turbine Enclosure roof sections are

shipped In four (4) pieces. The maintenance door railing
and weather hood will also be shipped in several boxes
and pallets.
Main Module Weights
Offloading
Royce
And all applicable parties. It is the Customer's
shelf locations.
Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
32
Completed Witnessed

for replacements.
the Packing Lists.
number.
Comments
Signatures / Date
Customer
Rolls-Royce
33
Completed Witnessed

arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
34
Completed Witnessed

Ventilation System (Inlet and Outlet)
Reference Documents
GEM 0144 - Receiving and Storage Instructions for Rolls
The air ventilation system is shipped as several bulk
modules and boxes that are required to complete one unit.
Main Module Weights
Offloading
Note: Note: Log all damages and shortages and notify
Rolls-Royce and all applicable parties. It is the Customer's
Comments
Signatures / Date
Customer
Rolls-Royce
35
Completed Witnessed

shelf locations.
Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
36
Completed Witnessed

for replacements.
the Packing Lists.
number.
arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
37
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
38
KENKO BOLIVIA- M.A606.01
Completed Witnessed
Activity 7 - Receiving Bleed (BOV)

Ductwork
Reference Documents
Inhibitor (VCI) Crystals for Rust Prevention GEM 0144 -
Receiving and Storage Instructions for Rolls- Royce
Rotating Equipment at Customer Site
Vendor literature
The Bleed (BOV) ducting is shipped as several bulk
Modules and boxes that are required to complete one unit.
Main Module Weights
Offloading
Comments
Signatures / Date
Customer
Rolls-Royce
39
Completed Witnessed

shelf locations.
Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
40
Completed Witnessed

for replacements.
the Packing Lists.
number.
arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
41
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
42
Completed Witnessed
Activity 8 - Receiving Exhaust

Transition Duct
Reference Documents
Main Module Weights
Offloading
shelf locations.
Comments
Signatures / Date
Customer
Rolls-Royce
43
Completed Witnessed

Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
44
Completed Witnessed

for replacements.
the Packing Lists.
number.
arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
45
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
46
Completed Witnessed
Activity 9 - Receiving Gas Turbine /

Generator Coupling
Reference Documents
Refer to Bibby vendor documentation for additional
Main Module Weights
Offloading
shelf locations.
Comments
Signatures / Date
Customer
Rolls-Royce
47
Completed Witnessed

Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
48
Completed Witnessed

for replacements.
the Packing Lists.
number.
arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
49
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
50
Completed Witnessed
Activity 10 - Receiving CO2 Cabinet
Reference Documents
Vendor literature
Refer to Det-Tronics vendor documentation for additional
Note: The CO2 cabinet will not be shipped with the CO2
bottles (12) installed. The bottles will be shipped in 6
separate boxes of 2 each.
Main Module Weights
Offloading
Comments
Signatures / Date
Customer
Rolls-Royce
51
Completed Witnessed

shelf locations.
Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
52
Completed Witnessed

for replacements.
the Packing Lists.
number.
arrived on site.
following
minimum requirements:
Comments
Signatures / Date
Customer
Rolls-Royce
53
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
54
Completed Witnessed

Mechanical Handling Skid
Reference documents
Main Module Weights
Offloading
shelf locations.
Comments
Signatures / Date
Customer
Rolls-Royce
55
Completed Witnessed

Customer present.
Note: Note: Periodic inspections are to take place on the
stored equipment to ensure that this remains in good
condition. Refer to the Manufactures or Vendors manuals
and drawings for periodic inspection requirements. Record
and document all periodic inspections.
Comments
Signatures / Date
Customer
Rolls-Royce
56
Completed Witnessed

for replacements.
the Packing Lists.
number.
arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
57
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
58
Completed Witnessed

Lube Oil Demister
Reference Documents
Main Module Weights
Offloading
shelf locations.
Comments
Signatures / Date
Customer
Rolls-Royce
59
Completed Witnessed

Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
60
Completed Witnessed

for replacements.
the Packing Lists.
number.
arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
61
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
62
Completed Witnessed
Activity 13 - Receiving A/C Generator

Lube Oil Console
Reference Documents
GEM 0144 - Receiving and Storage Instructions for
Rolls- Royce Rotating Equipment at Customer Site
Refer to the Mitten vendor documentation for additional
Main Module Weights
Please refer to the Rolls-Royce drawings listed above
for the weights of the major components. For more
Offloading
inspect all shipped material for signs of shipping
damage.
Comments
Signatures / Date
Customer
Rolls-Royce
63
Completed Witnessed

shelf locations.
Customer present.
2) It is the customer's responsibility to make provision
for the storage of the parts in a secure location that
provides protection from the elements, that is free from
sudden temperature changes that may cause moisture
invasion. It is also the customers responsibility to
maintain an inventory, including shelf locations, for all
the stored parts. Add protective compounds if
deterioration is observed as outlined in Rolls-Royce
Engineering Standards GEM 0143 and GEM 0144. For
more information, refer to chapter "Engineering
Standards, Forms, and Drawings."
Comments
Signatures / Date
Customer
Rolls-Royce
64
Completed Witnessed

for replacements.
the Packing Lists.
number.
arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
65
Completed Witnessed

12) Photograph all damage. If necessary, return
damaged material to Rolls-Royce.
Comments
Signatures / Date
Customer
Rolls-Royce
66
Completed Witnessed
Activity 14 - Receiving Shipped Loose

Items
Reference documents
Offloading
shelf locations.
Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
67
Completed Witnessed

Note: Note: Once the inventory has taken place, any
subsequent missing parts will be deemed to have been lost
at site, and the Project Manager will arrange to charge the
customer for replacements.
the Packing Lists.
number.
Comments
Signatures / Date
Customer
Rolls-Royce
68
Completed Witnessed

arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
69
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
70
Completed Witnessed
Activity 15 - Receiving Water Wash Cart
Reference documents
GED00196975 - Cart Water Wash
inhibitor (VCI) Crystals for Rust Prevention
Offloading
shelf locations.
Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
71
Completed Witnessed

for replacements.
the Packing Lists.
number.
Comments
Signatures / Date
Customer
Rolls-Royce
72
Completed Witnessed

arrived on site.
Comments
Signatures / Date
Customer
Rolls-Royce
73
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
74
Section II Controls / Electrical
Pre-commissioning
Activities
75
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Section II Introduction: Electrical Pre-

commissioning Activities
The following Controls/Electrical Pre-commissioning Activities are arranged sequentially and should be followed
in consecutive order. All pre-commissioning activities must be completed before proceeding to commissioning
activities covered in Chapter 3.
77
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Completed Witnessed
Activity 16 - Receive and Install Unit

Control Panel
Reference Documents
GED00220838 - ECS/SIS/PCS UCP Outline
GED00220839 - ECS/SIS/PCS UCP Control Schematic
GED00220841 - ECS/SIS/PCS UCP Panel Assembly
GER 0018 - Wiring System Engineering and Installation
GER 0198 - Signal Separation Requirements for Panels,
Packages, and Cross-site Wiring
GER 0035 - Rolls Royce Energy Customer Guidelines for
Cross- site Wiring
GER 0070 - Grounding / Earthing Design and Application
E555-000L-0511 - Design, Installation, and Commissioning
Guidelines for Industrial Control Systems
Within 14 days of the equipment arriving at site, a full
Customer present.
Project Team in Mt. Vernon. These will be investigated by
Comments
Signatures / Date
Customer
Rolls-Royce
79
Completed Witnessed
the Project Team in Mt. Vernon and will arrange for

replacements as required
Perform the following, in accordance with GEM 0144,
within the time allocated by the shipper for discovery of
damage and for filing claims. For more information, refer to
chapter "Engineering Standards, Forms, and Drawings."
1) A visual inspection for damage to the panels and
shipped loose items should be made upon receipt of the
equipment at the site.
2) If any damage exists, refer to the Assembly drawing
listed above, to identify the letter of the item balloon
associated with the damaged part. For more information,
refer to chapter "Engineering Standards, Forms, and
Drawings." The drawings and bill of material mentioned
above can be found in the manufacturer's Controls
instruction manuals. Locate the part number on the Bill of
Material and inform the Project Manager, or Site Electrical
lead to receive replacement parts.
3) If the cabinet location is not heated, provisions must be
made to control humidity and condensation. This can be
accomplished by installing a temporary heat source (light
bulbs, electric space heaters, etc.). Ensure the cabinet
temperature remains warmer than the ambient
temperature.
4) Unpack loose, shipped items and check off against the
packing list. If there are any shortages or damaged items,
they should be reported to the Mt. Vernon Project
Manager.
Installation of the cabinet
Comments
Signatures / Date
Customer
Rolls-Royce
80
Completed Witnessed
The sources of information about the control panel include

the technical manuals and project drawings which
document the construction of the cabinet. Verify the
drawings that are being used are being used are of latest
revision.
Please note that it is highly recommended to have one (1)
and only one (1) set of Master drawings used during the
commissioning process. Copies can be made to verify
circuits, but all marks should be transferred to the Master
set frequently. This will eliminate much of the confusion
and unnecessary repetitive checking during
commissioning.
Note: Changes to any of these drawings should be marked
up in Red (In) and Green (Out) and promptly returned to
Rolls-Royce Engineering.
Moving the cabinet
Safety Note: Tilting the cabinet more than 45°, front or
back, may damage the doors.
Based upon the number of cabinets, the equipment can be
moved into place using any one (1) of the following
methods:
o Fork Lift - while the equipment is attached to its original
shipping skid, it can be moved by fork lift to its final location
o Mobile Lifter - When using mobile lifters, the cabinet is
first removed from the shipping skid and placed on a
transport skid.
o Rollers - the cabinet can be moved to its final destination
using pipe rollers under the transport skid.
Comments
Signatures / Date
Customer
Rolls-Royce
81
Completed Witnessed
o Overhead crane - the cabinet can be lifted into place

using an overhead crane. Use the lifting eyebolts installed
on each cabinet as illustrated in the assembly drawings.
1) Prior to placing the control panel into its final position,
the control room must be clean and provisions must be
made to control humidity and condensation.
2) Place the cabinet in its final position.
3) Remove any packaging material from the panel.
Note: Some of the control panels contain a window that
protects the FT-210 or Local Display monitor which should
be left in place.
4) Check that all of the device mounting screws are present
and tight (screws can work loose during shipment).
5) Remove any packing braces or straps.
6) Note any missing or broken parts. Replacements should
be ordered without delay because many items used in the
panel have extended delivery times.
Comments
Signatures / Date
Customer
Rolls-Royce
82
Completed Witnessed
Activity 17 - Receive and Install Electric

Starter Controller Panel
Reference Documents
E00002754 - Vendor Drawing Ultra Electronic PMES
Electric Starter Controller Panel Installation
E555-000L-0511 - Design, Installation, and Commissioning
Guidelines for Industrial Control Systems
Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
83
Completed Witnessed

temperature.
Manager.
Installation of the cabinet
The sources of information about the control panel include
the technical manuals and project drawings which
document the construction of the cabinet. Verify the
drawings that are being used are being used are of latest
revision.
Comments
Signatures / Date
Customer
Rolls-Royce
84
Completed Witnessed
Please note that it is highly recommended to have one (1)

and only one (1) set of Master drawings used during the
commissioning process. Copies can be made to verify
circuits, but all marks should be transferred to the Master
set frequently. This will eliminate much of the confusion
and unnecessary repetitive checking during
commissioning.
Note: Changes to any of these drawings should be marked
up in Red (In) and Green (Out) and promptly returned to
Rolls-Royce Engineering.
Moving the cabinet
Safety Note: Tilting the cabinet more than 45°, front or
back, may damage the doors.
Based upon the number of cabinets, the equipment can be
moved into place using any one (1) of the following
methods:
o Fork Lift - while the equipment is attached to its original
shipping skid, it can be moved by fork lift to its final location
o Mobile Lifter - When using mobile lifters, the cabinet is
first removed from the shipping skid and placed on a
transport skid.
o Rollers - the cabinet can be moved to its final destination
using pipe rollers under the transport skid.
o Overhead crane - the cabinet can be lifted into place
using an overhead crane. Use the lifting eyebolts installed
on each cabinet as illustrated in the assembly drawings.
Comments
Signatures / Date
Customer
Rolls-Royce
85
Completed Witnessed
1) Prior to placing the control panel into its final position,

the control room must be clean and provisions must be
made to control humidity and condensation.
2) Place the cabinet in its final position.
3) Remove any packaging material from the panel.
Note: Some of the control panels contain a window that
protects the FT-210 or Local Display monitor which should
be left in place.
4) Check that all of the device mounting screws are present
and tight (screws can work loose during shipment).
5) Remove any packing braces or straps.
6) Note any missing or broken parts. Replacements should
be ordered without delay because many items used in the
panel have extended delivery times.
Comments
Signatures / Date
Customer
Rolls-Royce
86
Completed Witnessed
Activity 18 - Receive and Inspect Main

Control Room HMI (FT-210)
Reference Documents
GED00220843 - HMI Screen Shots
GED00228040 - ECS/SIS/PCS UCP Topology Diagram
Reference above drawings and vendor manual when
performing this activity. For more information, see chapter
Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
87
Completed Witnessed

temperature.
Manager.
Comments
Signatures / Date
Customer
Rolls-Royce
88
Completed Witnessed
Activity 19 - Receive and Inspect Air

Inlet Filter House Control Panel
Reference Documents
GED00226674 - Air Inlet Filter House (AIFH) Control Panel
Layout
Customer present.
Comments
Signatures / Date
Customer
Rolls-Royce
89
Completed Witnessed

temperature.
Manager.
Comments
Signatures / Date
Customer
Rolls-Royce
90
Completed Witnessed
Activity 20 - Provide Temporary Power

to All Motors, Generator, and Panels
Anti-condensation / Space Heaters
when on Storage
Reference Documents
GED00221291 - Electrical Interface
GER 0018 - Package Wiring System Engineering and
Installation Specification
Generator Vendor Literature
Generator Mineral Oil Skid Vendor Literature
Water Injection Skid Vendor Literature
ISI Skid Vendor Literature
Liquid Fuel Skid Vendor Literature
Procedure
Reference above drawings when performing this activity.
For more information, see chapter "Engineering Standards,
Comments
Signatures / Date
Customer
Rolls-Royce
91
Completed Witnessed

1) Inside heated storage is preferred, with temperature
maintained at least 10°F (6°C) above the dewpoint, relative
humidity of 50% or less, little dust accumulation and no
harmful fumes or substances.
2) If outside storage is the only option, a roofed structure is
recommended, with barrier protection in the direction of
prevailing weather conditions.
3) Space heaters, when provided, shall be activated.
4) Auxiliary equipment and parts boxes shall be placed on
timbers, under a temporary roof when possible and
covered with a tarpaulin arranged as to provide adequate
drainage and ventilation.
5) All electrical devices, including conduit, junction boxes,
controls, etc. shall be protected from condensation and
wind driven rain. If permeation occurs, open drains and
covers and blow dry.
6) The protective measures applied to parts boxes shall be
maintained. When it is necessary to open boxes in search
of parts, closure must be made in a manner which assures
that remaining parts are protected.
7) All protective measures applied must be maintained
during storage. Refer to the applicable Rolls-Royce Global
Engineering Standards.
8) Periodic inspections are to take place on the stored
Comments
Signatures / Date
Customer
Rolls-Royce
92
Completed Witnessed

9) Provide "Warning Sign" on all energized panel space
heaters, junction boxes and motors.
Comments
Signatures / Date
Customer
Rolls-Royce
93
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
94
Chapter 3 Installation
Activities
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Chapter Introduction
The Pre-commissioning Activities have been divided into Section I - Mechanical Pre-commissioning Activities
and Section II - Controls/Electrical Pre-commissioning Activities. Activities have been arranged sequentially and
should be performed in consecutive order. All Pre-commissioning Activities should be completed before pro-
gressing to Chapter 3 - Commissioning Activities.
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Completed Witnessed
Activity 21 - Check Foundation Blocks

and Datum
Reference documents
GEM 0033 - Setting and Grouting of Rotating Machinery
Including Use of Sole plates and Selection of Foundation
(Anchor) Bolts for Low Temperature Application
Installation
Prior to any Rolls-Royce equipment arriving at site, a site
survey is to be carried out by a Rolls-Royce representative
to ensure that the holding down bolts in the foundation
block are correct to drawing GED00221288. For more
Please refer to Rolls-Royce Engineering Standard GEM
0033 for the setting and grouting of rotating machinery and
the foundation preparation. For more information, refer to
Note: Ensure that any errors are rectified before the skid is
positioned on the foundation. If holding down bolt holes are
reworked ensure that written confirmation is received from
the civil contractor regarding foundation integrity after the
rework.
Comments
Signatures / Date
Customer
Rolls-Royce
99
Completed Witnessed
Note: The laying down of the datum's on the foundation

block is the responsibility of the contractor.
1) GT (Gas Turbine) skid holding down bolts
2) Generator skid holding down bolts
3) Mechanical handling skid holding down bolts
4) Check that all the areas of the foundation that will
subsequently come into contact with grout are clean, stable
and free from oil contamination. All suspect areas must be
chipped or scrabbled (roughened) to remove any
contamination or damage.
Comments
Signatures / Date
Customer
Rolls-Royce
100
Completed Witnessed
Activity 22 - Position the A/C Generator

Skid Over the Hold-down Bolts
Reference Documents
GED00230718 - Generator General Aggangement
GED00232632 - Generator Foundation Loading
Siemens Generator vendor information
Installation
Note: Depending upon which method is to be used to level
the baseplate, adjustable chocks, jacking bolts or shims
ensure that the correct hardware is in place at each jacking
point.
The equipment shall be set to ensure a minimum gap of
50mm (2 inches) between the foundation block and the
baseplates.
1) Ensure that the holding down bolts are inserted into the
bolt pockets in the foundation block as outlined in Rolls-
Royce Engineering Standard GEM 0033. For more
Comments
Signatures / Date
Customer
Rolls-Royce
101
Completed Witnessed

2) Lift the generator module using the baseplate lifting lugs
and the customer supplied lifting equipment.
3) Position the generator over its holding down bolts and
lower it down onto its jacking points.
4) Make final checks that the holding down bolts are
engaged fully and not tight in the baseplate hold down
holes.
Comments
Signatures / Date
Customer
Rolls-Royce
102
Completed Witnessed
Activity 23 - Position the Gas Turbine

Skid Over the Hold-down Bolts
Reference Documents
GED00199937 - Turbine Base
Installation
Note: Depending upon which method is to be used to level
the baseplate, adjustable chocks, jacking bolts, or shims
ensure that the correct hardware is in place at each jacking
point.
The equipment shall be set to ensure a minimum gap of 50
mm (2 inches) between the foundation block and the
baseplates.
1) Ensure that the holding down bolts are inserted into the
bolt pockets in the foundation block as outlined in GEM
0033. For more information, refer to chapter "Engineering
Comments
Signatures / Date
Customer
Rolls-Royce
103
Completed Witnessed
2) Lift the GT module using the baseplate hoist rings and

the customer supplied lifting equipment.
3) Position the GT module over its holding down bolts and
lower it down onto its jacking points.
4) Make final checks that the holding down bolts are
engaged fully and not tight in the baseplate hold down
holes.
Comments
Signatures / Date
Customer
Rolls-Royce
104
Completed Witnessed
Activity 24 - Leveling the Baseplates
Reference Documents
GED00199937 - Turbine Base
GEM 0032 - Tightening of Threaded Fasteners Torquing
Sequence for Flanged Joints and Rotabolt Applications
GEM 0045 - Skid Leveling Procedure
GEMF0045 - Skid Leveling Record Form
Installation
1) With the gas turbine (GT) baseplate in position, set the
dimension from the GT baseplate datum face to the
generator datum face.
2) Level the baseplate, according to Rolls-Royce
Engineering Standard GEM 0045, to each other using the
targets installed in the factory during build. For more
3) Refer to Siemens literature for the generator leveling
instructions.
Comments
Signatures / Date
Customer
Rolls-Royce
105
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
106
Completed Witnessed
Activity 25 - Install the GT Exhaust

Transition Duct
Reference documents
#4)
GEM 0123 Application of High Temperature Anti-Sieze
GEM 0034 GEM 0166 - Industrial Trent Exhaust Assembly
Procedure
GEM 0102 - Application of IGS High Temperature Sealant
and Gasket
AAF Vendor documentation and drawings
Installation
Note: Note: Apply high temperature sealant and fibre seal
to all mating flanges per standard GEM 0102
1) Lift the exhaust transition duct into position and attach
to the exhaust hood.
2) Align the flanges and install all the fasteners, then torque
up to the correct values.
3) Install insulation around the mating flanges. Retain with
Safety Wire
Comments
Signatures / Date
Customer
Rolls-Royce
107
Completed Witnessed
4) Install the AAF weathershroud
Comments
Signatures / Date
Customer
Rolls-Royce
108
Completed Witnessed
Activity 26 - Erect and Install the Gas

Turbine Roof Sections (4)
Reference Documents
GED00194621 - Enclosure - GT Acoustics (Starboard Side
Wall #2)
#1)
#2)
#3)
#4)
GED00194630 - Enclosure - GT Acoustics (Door Rail
Assembly)
Note: The Gas Turbine Enclosure roof sections are
shipped In four (4) pieces. The maintenance door railing
and weather hood Will also be shipped in several boxes
and pallets.
Installation
Comments
Signatures / Date
Customer
Rolls-Royce
109
Completed Witnessed
Please refer to the gas turbine (GT) acoustic vendor

documentation for the build sequence, drawings, and bills
of material.
1) Remove the shipping brackets from the enclosure, as
shown on Rolls-Royce drawing, prior to installing the roof
module. For more information, refer to chapter
2) Locate and bolt the combustion intake quick release
flexible connection underside of roof module #1 at ground
level.
3) Lift and bolt roof section #1 to the enclosure walls using
the AAF supplied spreader beam.
4) Lift and bolt flexible connection to the combustion intake
silencer. (roof section # 1)
5) Locate and bolt Bleed outlet quick release flexible
connection underside of roof module # 2 at ground level.
6) Lift and bolt the bleed duct roof section # 2 to the
enclosure walls using the AAF supplied spreader beam.
7) Lift and bolt roof section # 3 to the enclosure walls using
the AAF supplied spreader beam.
8) Bolt the maintenance sliding door runway system to
enclosure wall. Bolt the runway system weather hood into
place.
Note: Ensure that all the earth continuity devices have
been installed during erection.
Comments
Signatures / Date
Customer
Rolls-Royce
110
Completed Witnessed
Activity 27 - Install the AC Generator Air

Cooler Module
Reference Documents
GED00230718 - AC Generator General Arrangement
Siemens vendor documentation
Installation
Please refer to the Siemens vendor documentation for the
build sequence, drawings, and bills of material.
Note: Note: If at any time the fitting of the cooling system is
left unattended then the opening must be suitably covered
to ensure that no debris can enter, a thorough inspection
and, if required, cleaning must be carried out upon
recommencing
Note: Ensure that both the ventilation module and the AC
generator enclosure are clean and free from dust, vacuum
both clean if required. Both should be inspected by two (2)
Rolls-Royce site representatives before and after
installation, and signed for.
Comments
Signatures / Date
Customer
Rolls-Royce
111
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
112
Completed Witnessed
Activity 28 - Alignment Gas Turbine to A/

C Generator (Pre-Grout)
Reference Documents
GED00221295 - AC Generator Piping and Instrumentation
Diagram
GED00221298 - AC Generator Lube Oil Diagram
GTES 10245 - Industrial Trent 60 DLE and WLE DF
Interface
Control Document
GEM 0130 - Alignment Procedure - Rotalign® Pro Laser
Method
GEMF0130.A - Preliminary Alignment Check
GEMF0130.B - Alignment Diagram
Alignment Jig LOT94153
Bibby vendor documentation
Note: It is recommended that the AC generator jacking oil
system is available for the following procedure so that the
A/C Generator rotor can be rotated and set on its magnetic
center
Comments
Signatures / Date
Customer
Rolls-Royce
113
Completed Witnessed
Note: To align the Trent Gas Turbine to the Siemens A/C

generator requires Rolls-Royce special tooling alignment
jig LOT94153. The alignment tooling May only be used
under the supervision of a Rolls-Royce Field Service
Representative.
1) Ensure that the alignment jig is received in good
condition and that there is no damage. The jig will be
shipped disassembled in a transportation container. A
Rolls-Royce Field Service Representative will instruct the
site personnel how to assemble the alignment tooling.
2) Lift the assembled alignment jig into the package. A
forklift truck may be required to lift the jig into place at the
engine removal door.
3) Using an external lifter, lower the alignment jig into the
pillow blocks ensuring that the mortise and tenon engage
without binding.
4) By using the jacking feature at the bottom of the jig, set
the alignment jig dummy hub perpendicular using a
precision box level.
5) Set up the Rotalign in accordance with Rolls-Royce
Engineering Standard GEM 0130 on the alignment jig
dummy hub and the generator drive flange.
6) Carry out an alignment check and ensure that the
alignment is within the requirements of GTES 10245 (0.87
mRad). Move the A/C generator to achieve alignment. Do
not move the GT skid.
7) Using the setting flag supplied by the generator
manufacturer to ensure that the rotor is set on it's magnetic
centre. With the jacking oil on, the rotor should move back
Comments
Signatures / Date
Customer
Rolls-Royce
114
Completed Witnessed
and forth freely, when it is set, turn off the jacking oil to
ensure that the rotor will not move during the next check.
8) Using the special tooling internal micrometer measure
the distance between the dummy GT hub and the A/C
generator hub. Use this measurement to calculate the
coupling distance. If within limits coupling shims may be
added or removed. If not within tolerance, move the
generator.
Note: Refer to the Bibby coupling manual for calculating
shim changes.
9) Upon completion of the alignment remove the jig from
the unit. Disassembled the jib under the supervision of a
Rolls-Royce Field Service Representative. Insure the jig
parts are cleaned and oiled before storing into the special
shipping container.
Comments
Signatures / Date
Customer
Rolls-Royce
115
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
116
Completed Witnessed
Activity 29 - Grout the Gas Turbine and

A/C Generator Skids
Reference documents
GED00221287 - General arrangement
GED00221288 - Foundation and loading plan
Siemens Generator vendor documentation
Once the alignment has been completed, the baseplates
are to be grouted into position in accordance with Rolls-
information, refer to "Engineering standards".
The holding down bolts are customer supply, it is therefore
the customer's responsibility to provide a grouting
procedure and torque figures for the hold down bolts.
Comments
Signatures / Date
Customer
Rolls-Royce
117
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
118
Completed Witnessed
Activity 30 - Position the Gas Turbine

Mechanical Handling Skid and Grout
Reference Documents
GEM 0167 - Trent Mechanical Handling and Engine
Alignment
GEMF0075 - TRENT Phase III Alignment Form
Installation
1) Using Rolls-Royce Engineering Standard GEM 0167
install the GT mechanical handling skid.
2) Trial fit the engine removal trolley and check for free
movement.
3) Grout the mechanical handling skid in place and torque
down the holding down bolts.
4) Recheck the tooling trolley for free movement, if there is
any binding the external rails should be adjusted as these
will not have been dowelled in position during factory build.
Comments
Signatures / Date
Customer
Rolls-Royce
119
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
120
Completed Witnessed
Activity 31 - Load Test All Package

Supplied Lifting Equipment
Reference Documents
AAF Vendor manual and drawing
If required load test all Gas Turbine enclosure lifting
equipment. Insure the beams and eyes are marked
accordingly and the certification is included with the site
documentation.
Lifting Equipment
1) GT enclosure oil skid pump removal 1 x 500 Kg SWL
lifting eye
2) GT enclosure gas fuel valve removal 1 x 500 Kg SWL
lifting eye
3) GT enclosure Combustor (DLE) removal 1.0 ton SWL
fixed beam.
4) GT enclosure drive shaft installation, 1 x 500 Kg SWL
lifting eye
5) GT enclosure Drive shaft installation 1.0 ton SWL fixed
beam.
Comments
Signatures / Date
Customer
Rolls-Royce
121
Completed Witnessed
Safety Note: Ensure that all lifting equipment is in

good condition, has current certification and is oper-
ated by trained authorised personnel.
Comments
Signatures / Date
Customer
Rolls-Royce
122
Completed Witnessed
Activity 32 - Position and Install A/C

Generator Lube Oil Skid
Reference documents
GED00221295 - AC Generator Instrumentation Diagram
GED00221298 - A/C Generator Lube Oil Diagram
Including Use of Soleplates and Selection of Foundation
Bolts
Mitten Vendor Manual and Drawings
Siemens Vendor Manual and Drawings
Installation
1) Position the liquid fuel skid and grout into place in
accordance the vendor documentation and Rolls-Royce
Engineering Standard GEM 0033.
Comments
Signatures / Date
Customer
Rolls-Royce
123
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
124
Completed Witnessed
Activity 33 - Install the A/C Generator

Line and Neutral Cubicles
Reference documents
GED00221295 - AC Generator Instrumentation Diagram
GED00210366 - Utility Consumption List
GED00220845 - UCP Logic Flow Diagram
GED00220840 - Topology Diagram
GED00235373 - High Voltage Single Line Diagram
Siemens Vendor documentation
Installation
1) Lift and install the support structure onto the foundation.
2) Lift and install the AC generator line and neutral cubicles
in accordance with the generator's installation and
operating instructions.
Comments
Signatures / Date
Customer
Rolls-Royce
125
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
126
Completed Witnessed
Activity 34 - Erect and Install GT Bleed

Ductwork (BOV)
Reference Documents
GED00207859 - Trent 60 WLE Ventilation System
Diagram
Installation
Please refer to the AAF vendor documentation for the GT
Bleed Ductwork (BOV) build sequence, drawings, and bills
of material.
Note: If at any time the fitting of the bleed duct system is
left unattended then the opening must be suitably covered
to ensure that no debris can enter, a thorough inspection
and, if required, cleaning must be carried out upon
recommencing
Installation.
1) Locate and bolt the bleed outlet cowl to the Primary
silencer at ground level. Lift and this assembly Onto the
bleed duct roof section # 2.
Comments
Signatures / Date
Customer
Rolls-Royce
127
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
128
Completed Witnessed
Activity 35 - Erect and Install the Gas

Turbine Ventilation System (Inlet &
Outlet)
Reference Documents
GED00207859 - Gas Turbine Ventilation System Diagram
Installation
Please refer to the AAF vendor documentation for the
Turbine ventilation system ductwork build sequence,
drawings, and bills of material.
Note: If at any time the fitting of the ventilation duct system
is left unattended then the opening must be suitably
covered to ensure that no debris can enter, a thorough
inspection and, if required, cleaning must be carried out
upon recommencing
Installation.
Ventilation Inlet System
1 Lift and bolt the vent inlet bend onto the GT enclosure
front wall panel.
2) Lift and bolt the vent inlet damper vent inlet bend.
Comments
Signatures / Date
Customer
Rolls-Royce
129
Completed Witnessed
3) Lift and bolt the vent inlet silencer onto vent inlet
Damper.
4) Lift and bolt the vent inlet vertical duct onto vent inlet
Silencer. Bolt supports into place.
5) Lift and bolt flexible connection to the vent inlet silencer.
Ventilation Outlet System
1) Lift and bolt outlet fans (3) onto the vent outlet mixing
Box.
2) Lift and bolt the vent outlet silencer onto the vent fan
assemblies.
Comments
Signatures / Date
Customer
Rolls-Royce
130
Completed Witnessed
Activity 36 - Install the Air Filter House
Reference Documents
Diagram
GED00207859 - Trent 60 WLE Ventilation System
Diagram
GED00207950 - Trent 60 WLE Instrument Air and
Demineralizrd System
GEM 0034 - Lockwiring Procedure
GEM 0043 - Application of RTV-106 Adhesive Sealant
AAF Air Intake vendor documentation
Caldwell Fogging manual and drawings.
Installation
Assemble the filter house sections at ground level and lift
into place. Follow the detailed instructions given in the AAF
vendor manual and drawings.
Note: Field fabricate a temporary support base at ground
level to suit the footprint of the air filter house. Insure the
support is level.
1) Locate and assemble the four (4) assemblies that make
up the transition module. (Lower rear, Lower front, upper
rear, and upper front)
2) Locate and bolt the fogging duct floor panel to the lower
intake bend.
Comments
Signatures / Date
Customer
Rolls-Royce
131
Completed Witnessed
3) Locate and bolt the fogging duct internal divider wall to

intake bend and fogging panels. Weld the panels per the
AAF drawing.
4) Locate and assemble the fogging duct roof panels. Bolt
roof panel assembly to fogging duct wall panels and
transition.
Note: Install the four stays (braces) supplied by Caldwell.
The fogging tubing can be installed later. Refer to the Rolls-
Royce drawings GED00018412, Caldwell vendor fogging
manual and drawings.
5) Locate and bolt lower ASC section to the fogging duct.
Tack weld the hardware per the AAF drawing.
6) Locate and bolt upper ASC section to lower ASC section
and the fogging duct. Tack weld the hardware per the AAF
drawing.
7) Locate and bolt lower service plenum to lower ASC
section.
8) Locate and bolt upper service plenum to upper ASC
section and lower service plenum.
9) At ground level locate and bolt secondary air fan
assembly to secondary air dust chute.
The fan is attached with rubber isolators and threaded
rod. Lift this assembly onto the air filter house support
structure. Temperately support this assembly using field
fabricated supports, slings, etc.
10) Complete the installation of the Caldwell fogging
system. Install the fogging tubing per the Caldwell manual
and drawings.
Comments
Signatures / Date
Customer
Rolls-Royce
132
Completed Witnessed
11) The air filter house assembly is now ready to be lifted

and set onto the main support structure.
Note: Do not install the air filter elements at this time. Due
to weight constraints the filter elements can only be
installed after the assembly is set onto the support
structure.
Note: Prior to lifting verify the following:
1) All the joints, particularly down stream of the filter
elements, to ensure a perfect seal. Use an appropriate
mastic to ensure the integrity of the seals.
2) All the bolts are fitted and tighten up to the correct
torque.
3) All fasteners downstream of the filter elements on the
combustion air system have been positively locked either
by Tack welds or lock wired.
4) All fogging system fittings, nozzles, and supports are
either tack welded or lock wired.
5) All the earth continuity devices have been installed.
6) The filter house has been cleaned, all access doors
should be sealed, and any entry forbidden to prevent re-
contamination.
Safety Note: 1) The weather conditions and forecast is
to be taken into account when lifting large sections. Do
not lift large objects in high wind.
Safety Note: 2) When using cranes, stacker trucks,
hoists and other lifting equipment, ensure that only
equipment that is currently certified, in good order and
Comments
Signatures / Date
Customer
Rolls-Royce
133
Completed Witnessed
operated by authorised, trained personnel is used. A

banksman must be used when a crane is in operation.
Ensure that all personnel involved in lifting operations
are aware of the risks involved and that all the control
measures identified by the Site Risk Assessment are in
place.
12) Lift the assembled air filter house using the supplied
lifting equipment and set onto the main
Support structure.
a) Bolt the lower intake bend to beams.
b) Bolt the fogging duct to beams.
c) Bolts the lower ASC to support Saddles.
d) Bolt the lower service plenum to beams.
e) bolt the lower ASC to secondary air dust chute.
13) Bolt the intake transition supports to the Vent outlet
cowl.
14) Bolt the vent inlet flexible joint to the air filter house.
15) Bolt the combustion air inlet flexible joint to the air filter
house.
16) At ground level bolt the roof handrails to their supports.
Lift and bolt onto the enclosure roof. Lift and bolt the
access ladder into place.
17) At ground level bolt the roof handrails to their supports.
Lift and bolt onto the enclosure roof. Lift and bolt the
access ladder into place.
Comments
Signatures / Date
Customer
Rolls-Royce
134
Completed Witnessed
18) Install the air filter elements and perform a final

cleaning.
Note: After the filter house has been cleaned and a "white
Glove" inspection performed all access doors should be
sealed, and any entry forbidden to prevent contamination.
Any foreign debris left downstream of the filter elements
may result in a catastrophic failure of the gas turbine.
Comments
Signatures / Date
Customer
Rolls-Royce
135
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
136
Completed Witnessed
Activity 37 - Erect and Install Air Filter

House Structure
Reference Documents
Diagram
GED00207859 - Trent 60 WLE Ventilation SystemDiagram
GED00207950 - Trent 60 WLE Instrument Air and
Demineralizrd System
GEM 0034 - Lockwiring Procedure
GEM 0043 - Application of RTV-106 Adhesive Sealant
AAF Air Intake vendor documentation
Installation
1) Locate and bolt the intake support steelwork columns (6)
to the foundation anchor points.
2) Locate and bolt the intake support steelwork beams to
steelwork columns.
3) Locate and bolt the intake support steelwork circular
bracing to steelwork columns and beams.
4) Locate and bolt the intake support steelwork circular
bracing to steelwork columns and beams.
5) Locate and bolt the intake support steelwork bracing and
ASC support feet to steelwork beams.
6) At ground level locate and bolt together the lower and
upper access platforms and handrails.
Comments
Signatures / Date
Customer
Rolls-Royce
137
Completed Witnessed
7) Locate and bolt the lower platform and stays to support

steelwork.
8) Locate and bolt the upper platform to support steelwork.
9) Locate and bolt the access ladders and their supports to
the lower and upper platform steelwork.
Comments
Signatures / Date
Customer
Rolls-Royce
138
Completed Witnessed
Activity 38 - Position and Install CO2

Skid
Reference Documents
GED00207956 - Fire and Gas System Diagram
Det-Tronics Vender Information
Installation
1) Position the CO2 cabinet and grout into place in
accordance the vendor documentation and Rolls-Royce
2) Connect the CO2 interconnecting pipe work
3) Load the bottles. When charged, each bottle will weigh
45.5 Kg (100 lbs.).
Note: For the GT enclosure, there are eight (8) main and
eight (8) reserve bottles.
Comments
Signatures / Date
Customer
Rolls-Royce
139
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
140
Completed Witnessed
Activity 39 - Install Flexible Drive Shaft

Coupling
Reference Documents
Bibby vendor documentation
GEM 0109 - Trent Phase III Package Gas Turbine
Installation
Rolls-Royce Special Tooling LOT 95154
Prerequisites
1) The gas turbine mechanical handling rail system has
been Commissioned and is functioning correctly. The GT
Berthing assembly is fully assembled in the rail system and
functioning correctly.
2) The coupling final shim pack setting has been
determined, and the GT is not installed in the package.
3) Two (2) 500Kg (.5 ton) hoists connected to the lifting
positions in the interface module above the exhaust front
and rear flanges.
4) Both package sliding doors are fully open.
Installation
Comments
Signatures / Date
Customer
Rolls-Royce
141
Completed Witnessed
Note: To install the Bibby flexible drive shaft coupling

requires Rolls-Royce special tooling LOT 94154. The
installation tooling may only be used under the supervision
of a Rolls-Royce Field Service Representative.
1) Ensure that the tooling is received in good condition and
that there is no damage. The tooling will be shipped
disassembled in a transportation container. A Rolls-Royce
Field Service Representative will instruct the site personnel
how to assemble the alignment tooling.
2) Install the rear support and stabilizers at the aft side of
the GT exhaust.
3) Install the front support at the forward side of the GT
exhaust. Lift and position and secure the main railing
between the two supports.
4) Assemble the A-Frame and using suitable lifting
equipment position it onto the GT berthing tool. Set the two
(2) carriers onto the A-Frame rails. Install the carrier spacer
bar.
5) Move the GT berthing tool into the enclosure and align
the A-Frame to the main railing. Position and secure the
bridging rail to the to the main rail and A-Frame. Test the
carrier/spacer by moving it down the railing. It should move
smoothly. Adjust as required.
6) Move the GT berthing tool back out from the enclosure.
Lift the coupling drive shaft onto the A-Frame carriers.
Move the berthing tool back into the enclosure and align
the railings.
7) Move the carrier/coupling along the railing and into
position. Using the hoists lift the coupling off
Comments
Signatures / Date
Customer
Rolls-Royce
142
Completed Witnessed
The A-Frame. Push the carrier out and onto the A-frame.
Move the berthing tool out of the enclosure. The coupling is
left supported by the hoist at the forward end until the GT is
installed.
8) Disassembled the tooling in the revere of the assembly.
Insure the tooling parts are cleaned and oiled before
storing into the special shipping container.
9) The GT can now be installed in accordance with activity
"Gas Turbine Installation".
Comments
Signatures / Date
Customer
Rolls-Royce
143
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
144
Completed Witnessed
Activity 40 - Install Gas Turbine in Berth
Reference Documents
GEM 0034 - Lock Wiring Procedure
GEM 0167 - TRENT Mechanical Handling and Engine
Alignment
Installation
GER - 0118 Installation and removal of Trent GT Transport
stand
GTER 10205 - Gas Turbine/Package Interface Checks
TRPED 3045 Site Commissioning Installation of a Trent
Gas Turbine Change out Kit LOT93297
Gas Turbine Lifter FPDLE LOT94127 or LOT94144
Transportation Stand Lifter FPDLE LOT94130 or
LOT92282
Gas Turbine Lifter FPWLE LOT94146
Transportation Stand LOT92263 or LOT92284
Transportation Stand Lifter FPWLE LOT92291
Comments
Signatures / Date
Customer
Rolls-Royce
145
Completed Witnessed
Note: Ensure that good fitting practices are carried out at

all times. Interfaces should not be left open after the blanks
have been removed to ensure that the systems remain
uncontaminated. Use only the correct hand tools suitable
for the job.
Prerequisites
1) The Gas Turbine is in its transportation stand
LOT92263, LOT92284, or LOT92263 parked adjacent to
the package but clear of the Gas Turbine handling skid.
2) The sliding maintenance doors are open and the
Mechanical Handling Skid is attached to the GT base plate.
3) The coupling drive shaft is position inside the exhaust
hood.
Installation
1) Assemble the berthing tool and set onto mechanical
handling rails. Assembly the GT change out kit LOT93297
onto the berthing tool.
2) Move the air intake plenum forward and locked in its
Gas Turbine change out position.
3) Retract the bleed plenum expansion bellows to its
compressed state.
4) Insure the Exhaust inner and outer sliding diffusers are
fully retracted.
5) Remove the Gas Turbine rear pedestal mount on the
entry side.
6) Fit the rear trunnion pins and colletts onto the GT.
Comments
Signatures / Date
Customer
Rolls-Royce
146
Completed Witnessed
7) Install the Transition Scroll RRE009265 (Dog Dish) to

the front of the Gas Turbine with the fasteners. Lock wire in
position.
8) Open the middle section of bleed plenum covers and
attach the lifting clevis.
9) The GT front mount assembly is to be laid down towards
the rear with the bearing top caps slackened off.
10) Remove both rear pedestal mounts pillow block top
bearing caps. Insure the mortise, with the Gas Turbine
tennon inserted, is pushed rearward clear of the rail system
with its location dowels and holding down bolts safely
secured.
11) Remove or lower all potential clashing fixtures within
the GT installation envelope.
12) Remove the Environmental Protection cover from the
GT and prepare the GT for lifting out the transportation
stand in accordance with GER 0118. Lift and set the GT
onto the berthing tool. Secure the GT to the berthing tool
hydraulic jacks and Disconnect the GT lifter.
13) Move the GT into the enclosure. Reinstall the rear
pedestal mount on the entry side.
14) Using the hydraulic jacks lower the GT into position
and secure the rear trunnions and front mount.
15) Move the berthing tool out of the enclosure. Dissemble
and store the tooling.
16) Remove the rear rail centre section and install the rear
GT mount mortise. Ensure the mortise mounting interface
location on the baseplate is wiped clean and free from
Comments
Signatures / Date
Customer
Rolls-Royce
147
Completed Witnessed
debris or burrs, and lightly oiled. Ensure the mortise /

tennon mating faces are also lightly oiled and the tennon
slides freely. With the tennon positioned rearward in the
mortise, carefully slide the mortise into position so that the
dowels can be inserted.
17) Using an engineer's precision box level on the GT
coupling hub flange check GT is horizontal and change
shims accordingly to elevate the front mount as required.
18) A distance between shaft ends should be taken
between Gas Turbine and the A.C. Generator to determine
the coupling final shim pack setting.
19) Install the GT coupling hub spacer. Secure with the
provided hardware.
20) At this point the coupling can be connected to the
generator flange and the GT flange.
21) Torque all bolts per the Bibby manual and drawings.
Note: The jacking and compression screws, fitted for
transportation, must be removed prior to operation as per
the Bibby coupling instructions.
Comments
Signatures / Date
Customer
Rolls-Royce
148
Completed Witnessed
Activity 41 - Package Gas Turbine

Alignment - Final Check
Reference Documents
Installation
GEM 0167 - TRENT Mechanical Handling and Engine
Alignment
GEM 0130 - Alignment Procedure - Rotalign® Pro Laser
Method
GEMF 0130.A - Preliminary Alignment Check
GEMF 0130.B - Alignment Diagram
Siemens A/C Generator vendor documentation
Note: It is recommended that the AC generator jacking oil
system is available for the following procedure so that the
A/C Generator rotor can be rotated.
Prerequisites
The contract GT is to be the aligning tool. Therefore the GT
is to be installed prior to the alignment and the coupling
driveshaft bolted in place.
Note: The driveshaft is shipped with 16 0.015" shims, 8 are
in the driveshaft, split 4 at each end which are included in
the cold installed DBFF dimension
Comments
Signatures / Date
Customer
Rolls-Royce
149
Completed Witnessed
Alignment
1) Set up the Rotalign in accordance with Rolls-Royce
2) Commence the alignment check using the Rotalign Per
GEM 0130.
3) Continue alignment checks until the alignment is within
the required Limits and the DBFF distance is correct.
4) Insure all base plate hold down bolts are torqued.
Comments
Signatures / Date
Customer
Rolls-Royce
150
Completed Witnessed
Activity 42 - Gas Turbine Interface

Connections / Air, Water, Fuel, Lube &
Hydraulic Oil.
Reference Documents
GED00207861 - Engine Ignition and Instrumentation
Diagram
GED00207857 - Trent 60 WLE Combustion Air Diagram
GED00207951 - Trent 60 WLE Fuel Gas System
GED00207950 - Trent 60 WLE Instrument Air Diagram
GED00207946 - Trent 60 WLE P30 Purge Air System
GED00207955 - Trent 60 Water Wash Diagram
GEM 0032 - Tighten Threaded Fasteners
GEM 0088 - Handling and installing flexible hoses
GTER 10205 - Gas Turbine/Package Interface Checks
Note: Refer to the drawings for parts details and
connection procedures.Support tubing, piping, and hoses
with the supplied supports. Various tubing and piping
connection will require field fitting.Insure o-rings, gaskets,
and seals are installed correctly.
Connections
1) Move the air intake plenum aft and lock in its Gas Turbine
running position. Connect the inlet flare To the GT with the
Comments
Signatures / Date
Customer
Rolls-Royce
151
Completed Witnessed
large v-clamp. Confirm correct alignment of the GT to intake

scroll has been carried out. Confirm that the gap of 15mm
between the Centre body extension piece and the Transition
flange has been set. Check the flow path alignment of the
Extension piece with the Transition flange.
2) Extend the plenum expansion bellows and lock into
position. Connect all hoses and tubing to the inlet flare.
3) Extend the bleed plenum expansion bellows and lock into
position.
4) Extend the Exhaust inner and outer sliding diffusers and
secure into position. Confirm correct alignment of the GT to
the exhaust diffusers has been carried out. Remove all
special tooling. Install insulation as required.
5) Install the electric starter motor onto the Gas Turbine.
Connect the oil cooling hoses.
6) Connect all lube oil hose to the Gas Turbine lube oil pump.
7) Connect all hydraulic control oil hose to the Gas Turbine.
8) Connect all instrument air tubing to the Gas Turbine.
9) Connect all Liquid and gas fuel piping to the Gas Turbine.
10) Connect all Cooling air piping and hoses to the Gas
Turbine.
11) Connect all oil vent and demister tubing and piping to the
Gas Turbine.
12) With the assistance of a Rolls-Royce Control technician
connect all cannon plug type cables to the Gas Turbine.
Mount all ship loose junction boxes and instruments.
Comments
Signatures / Date
Customer
Rolls-Royce
152
KENKO BOLIVIA -M.A606.01
Completed Witnessed
Activity 43 - Installation of the Enclosure

Heater
Reference Documents
Installation
1) Lift and attach the heater to the enclosure roof. Cut the
mounting Tubing to fit.
2) If the mounting brackets of the heater chassis do not lie
flat before the nuts are tightened, use additional washers
as shims, so that it is level when you tighten the nuts.
3) The connection wiring should pass through the glanding
chamber provided.
Comments
Signatures / Date
Customer
Rolls-Royce
153
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
154
Completed Witnessed
Activity 44 - Erect and Install Gas

Turbine Lube Oil Demister
Reference Documents
GED00207861 - Engine Ignition and Instrumentation
Diagram
GED00207863 - Trent 60 WLE Gas Turbine Lube Oil System
Diagram
GED00219251 - Lube Oil - Gas Turbine
GED00194693 - Piping - Mist Eliminator lower
GED00194743 - Piping - Mist Eliminator roof
Installation
1) Lift and install the demister support onto the enclosure
roof.
2) Install the demister onto the support.
3) Install the ship loose demister inlet pipe and closing plate.
4) Using the supplied tubing and fittings, cut and bend the
drain tubing to fit.
5) Seal weld the vent inlet pipe to the closing plate.
Note: Quality Notes
All Pipework shall be cleaned in accordance with the Rolls-
Royce Engineering Standard GEM 0037 (latest revision.All
Comments
Signatures / Date
Customer
Rolls-Royce
155
Completed Witnessed
"torque" values are to be as per the Rolls-Royce engineering

Standard GEM 0032 (latest revision). For more information,
Drawings."
Comments
Signatures / Date
Customer
Rolls-Royce
156
Completed Witnessed
Activity 45 - Installation of Cross Site

Cables
Reference Documents
GED00220839 - ECS/SIS/PCS UCP Control
Schematic
GED00221307 - Cable Routing Information
GED00226679 - Air Inlet Filter House Electrical
Installation
GED00196976 - Fire and Gas Wiring
GEM 0047 - Procedure for Electrical Testing of a
Package prior to Operational Testing
GEM 0084 - Installation of Electrical Conduit and Wiring
GEM 0111 - Guidelines for Repairing Damaged Cable
GER 0035 - Rolls-Royce Energy Customer Guidelines
for Cross Site Wiring
Comments
Signatures / Date
Customer
Rolls-Royce
157
Completed Witnessed
GER 0070 - Grounding / Earthing Design and

Application
Packages, and Cross Site Wiring
Vendor Literature
Entronics Installation Manual E555-000L-0511 Vendor
literature Rolls-Royce Controls Installation Manual
Installation Notes
Note: Any factory installed wires that are damaged, must
be repaired or replaced according to the requirements
outlined in Rolls-Royce Engineering Standard GEM 0111.
For more information, refer to chapter "Engineering
Others are responsible for the installation of cabling
between the various skid edge terminal boxes, the
panels, and the MCC (Motor Control Centre). The
assembly and outline drawings listed above contain the
necessary details to aid in the cable routing.
The following paragraphs contain items that should be
taken into consideration to reduce problems later on.
I. EMI/RFI (electromagnetic and radio frequency
interference) In some situations, the proposed site may
experience EMI or RFI interference which can result
from nearby radio frequency sources (for example, two-
way radios, TV, or radio transmitters) or industrial
equipment (such as arc welders, fluorescent lights, or
Comments
Signatures / Date
Customer
Rolls-Royce
158
Completed Witnessed
electronic air cleaners). Sources of EMI include electric

floor heaters, transformers, variable frequency drives
and rotating machinery (such as fans or drills) and
power distribution lines. The effects of RFI and EMI can
be reduced or eliminated by properly shielding and
grounding the cables and equipment chassis, and by
routing the cables away from potential interference
sources.
II. Planning for Power and Grounding
Guidelines for complying with required electrical codes
are listed below:
a) All plant wiring (including power and signal cables)
must be installed in accordance with the NEC, CEC, or
other local regulations.
b) Power wiring must conform to the local electrical
code. Use of a qualified contractor and approval by the
local wiring inspector ensures compliance to this code.
c) Power wiring and signal cables installed by Rolls-
Royce will conform to the NEC or CEC standards.
d) Maintain signal separation.
III. Signal classification
Note: These classifications and spacing recommendations
should be followed at the entire job site, not just within the
control room and panel.
Comments
Signatures / Date
Customer
Rolls-Royce
159
Completed Witnessed
IEEE Standard 518-1982 recommends dividing the

wiring into four (4) levels with level one (1) as the most
sensitive and level four (4) as the least sensitive.
Sensitivity and noise generally are opposite so you
could also say that level four (4) is the noisiest and level
one (1) is the quietest.
The following are the classifications followed by
examples of typical Rolls-Royce signals that would be
in that level.
Level 1 - High Susceptibility
These are analog signals <50 V or digital signals <15
V.
These include:
a) RTD (Resistance Temperature Detector) inputs
b) Speed Inputs
c) Analog voltage inputs
d) Serial and LAN (Local Area Network) cables
e) Vibration inputs and proximitors
f) Vibration transducer inputs
g) Current loop inputs either 4 to 20 mA or 0 to 20 mA
h) Thermocouple inputs including the cold junction
compensators where applicable
Comments
Signatures / Date
Customer
Rolls-Royce
160
Completed Witnessed
i) LVDT (Linear Variable Data Transmitter) and RVDT

(Rotary Variable Data Transmitter) inputs
j) 24 VDC power to transmitters but NOT to solenoids -
what Rolls-Royce would typically call "clean" power.
Level 2 - Medium Susceptibility
Analog signals greater than 50 V and switching circuits
less than 50 V and > 15 V with small currents.
a) Digital inputs
b) Digital outputs
c) Power to the UV (Ultraviolet) fire detectors
d) "Dirty" DC power to the panel if it is < 20 A
e) 24 VDC power to low power switching devices such
as relays and solenoids
Level 3 - Low Susceptibility
Signals greater than 50 V and less than 20 A, AC and
DC feeders less than 20 A.
a) The 24 VDC power to the oil system motor controller
b) 24 V "Dirty" DC power to the panel if it is > 20 A
c) Power to the igniters - this is an especially noisy
signal and must be run in shielded twisted pair cable.
d) Power to fluorescent lights - these are also
particularly noisy and should always be run in conduit.
Comments
Signatures / Date
Customer
Rolls-Royce
161
Completed Witnessed
It is also recommended that the fixtures should be of

the shielded design.
Level 4 - Power
Any wire with more than 20 A and any AC power over
50 V.
a) Power to the EMV (Electric Metering Valve)
b) AC power feeding the panel
c) DC power supplied to the panel should also be kept
separate from all AC power.
Routing the different levels
1) Only run wires of the same class together, especially
IS and non-IS wiring.
2) Level one (1) should always be run in shielded
twisted wire.
3) Level two (2) should be run in shielded twisted wire
whenever possible.
4) If wires must cross, they should cross at right angles.
The following tables define the spacing
recommendations for the different wiring classes. The
tables are broken down into tray spacing, tray-conduit
spacing, and conduit spacing.
Table 1 - Tray Spacing
Comments
Signatures / Date
Customer
Rolls-Royce
162
Completed Witnessed
Level 1 2 3 4
1 0 Note a 6” (15.24 26”

cm) (66.04
cm)
2 Note a 0 6” (15.24 18”

cm) (45.72
cm)
3 6” (15.24 6” (15.24 0 Note b

cm) cm)
4 26” 18” Note b 0

(66.04 (45.72
cm) cm)
a. When levels one (1) and two (2) are run side by side
in trays, a one inch (2.54 cm) minimum spacing is
required and must be in shielded twisted pair wiring
b. Levels three (3) and four (4) may be run in a common
tray, but should be separated by a steel barrier. The
spacing should be Level four (4) and the barrier does
not have to be grounded.
Comments
Signatures / Date
Customer
Rolls-Royce
163
Completed Witnessed
Table 2 – Tray-Conduit Spacing
Level 1 2 3 4
1 0 1" (2.54 4” (10.16 18”

cm) cm) (45.72
cm)
2 1" (2.54 0 4” (10.16 12”

cm) cm) (30.48
cm)
3 4” (10.16 4” (10.16 0 0
cm) cm)
4 18” 12” 0 0
(45.72 (30.48
cm) cm)
Table 3 – Conduit Spacing
Level 1 2 3 4
1 0 1" (2.54 3” (7.62 12”

cm) cm) (30.48
cm)
Comments
Signatures / Date
Customer
Rolls-Royce
164
Completed Witnessed
2 1" (2.54 0 3” (7.62 9” (22.86

cm) cm) cm)
3 3” (7.62 3” (7.62 0 0
cm) cm)
4 12” 9” (22.86 0 0
(30.48 cm)
cm)
IV. Cable Tray Installation
1) Ensure that the cable tray is of sufficient width and is
cut to allow for the proper bend radius of the cables that
it is to support. Typical cables require a minimum of 6x -
8x the diameter of the cable to make a 90-degree bend
as outlined in Rolls-Royce Engineering Standard GER
0018. This prevents damage to the internal conductors
as well any the insulation. Review the cable
manufacturers recommendations and the above
drawings.
2) Ensure that all cable trays are properly supported
and fastened to hold the weight of the cables as well as
any loading that may be placed upon them. Be aware
of traffic areas that may require extra support of cable
tray covers.
3) Install cable tray ends where the cable trays are
connected or are cut to prevent damage to the cables.
Comments
Signatures / Date
Customer
Rolls-Royce
165
Completed Witnessed
4) Install proper bonding cables to each piece of cable

tray and to site earth ground. Ensure that the grounding
conductors are of the appropriate size and colour as
depicted in the appropriate drawings.
5) Ensure proper division of AC voltages, DC
instrumentation, and Intrinsically Safe (IS) signals are
maintained when laying out cable trays and installing
cables.
Install Cable Tray to the Following Locations as
Required:
1) GT Enclosure ventilation fans and instrumentation
2) Fire System beacons and sounders
3) Fire System CO2 skids
4) Combustion air inlet pulsing system and lighting
5) Water injection skid
6) Inlet Spray Intercooler skid
7) Liquid Fuel skid
8) Generator skid
9) Generator Lube Oil skid
10) SCR skid
11) SCR / CEMS enclosure
V. Instrument / Control Cable Installation
Comments
Signatures / Date
Customer
Rolls-Royce
166
Completed Witnessed
1) During field wire termination, ensure that one (1) end

of each shielded pair is grounded in the cabinet only. If
this is not feasible for some devices, then the shield
may be terminated in the field. However, in either
instance, the shield is to be terminated at one (1) end
only. This recommendation is based on considerations
of signal degradation and noise immunity in typical
industrial environments as described in Design,
installation, and commissioning guidelines for ndustrial
control systems. For more information, refer to chapter
2) Some control cables use a Mylar wrap for noise
reduction purposes that separate the shielded wire
pairs. To eliminate any ground problems due to the
Mylar wrap separating, it is recommended that heat
shrink-wrap be used throughout the field wiring
termination process. Each individual shield, with each
pair, should have a smaller size heat shrink tube
installed on it prior to termination.
3) The shield should not come in contact with other
shields.
4) The shield should cover to within two (2) inches (5
cm) of the termination point.
5) All cores to be identified and tagged in accordance
with the drawings, and +/- polarities to be labeled
where critical.
Comments
Signatures / Date
Customer
Rolls-Royce
167
Completed Witnessed
6) All earth cores are to be coloured green/yellow or

sleeved green/yellow at termination points.
7) All screen drain wires are to be insulated with green
heat shrink, and all screens shown not connected at
devices must be insulated and tied back.
8) Instrument and IS grounding cables must have
continuity from the field device to the panel where the
respective ground connection is only in the panel.
9) All cable glands and conduit connectors are to be
fitted with locknuts, sealing washers, serrated washers
and earth tags as required except when terminating at
EXD or EEXD certified equipment where sealing
washers are not permitted, and serrated washers are
not required.
10) Coat all cable gland threads with copper anti-seize
before installation.
11) All cable glands terminating at untapped gland
plates in the field are to be fitted with hubs instead of
lock nuts.
12) The spare cables should be identified by tags,
coiled up and then stored underneath the cabinet.
Terminated and spare wire pairs should be treated in
the same manner as outlined in the procedure and
linked to earth at the control system.
13) Earthing and bonding to be carried out in
accordance with the above listed engineering
Comments
Signatures / Date
Customer
Rolls-Royce
168
Completed Witnessed
standards. For more information, refer to chapter

VI. Low and Medium Voltage Power Cable
Installation
1) Power wiring must conform to the local electrical
code. Use of a qualified contractor and approval by the
local wiring inspector ensures compliance to this code.
2) For many Variable Frequency Drive installations,
unshielded power cable to motor is adequate, provided
it can be separated from sensitive circuits. As an
approximate guide, allow a spacing of 0.3 meters (1
foot) for every 10 meters (32.8 feet) of length. In all
cases, long parallel runs must be avoided. Do not use
cable with an insulation thickness less than or equal to
15 mils (0.4mm/0.015 in.). Use Copper wire only. Wire
gauge requirements and recommendations are based
on 75° C. Do not reduce wire gauge when using higher
temperature wire. See VFD vendor literature for more
details.
Comments
Signatures / Date
Customer
Rolls-Royce
169
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
170
Completed Witnessed
Activity 46 - Unit Control Panel

Electrical, Control and Communication
Cables Interconnect
Reference Documents
Schematic
GED00226679 - Air Inlet Filter House Electrical
Installation
GED00146777 - Fire and Gas Wiring Assembly
GEM 0047 - Procedure for Electrical Testing of a Package
prior to Operational Testing
Comments
Signatures / Date
Customer
Rolls-Royce
171
Completed Witnessed

Application
Installation
1) During the installation and commissioning process, a
buzzer can be placed between the "clean" and "dirty" ground
bars. If the buzzer rings, that would indicate a ground fault. It
could be much easier to find a fault early in the installation
and commissioning process than at the end. After the
installation is complete, remove the buzzer.
2) During field wire termination, ensure that one (1) end of
each shielded pair is grounded in the cabinet only. If this is
not feasible for some devices, then the shield may be
terminated in the field. However, in either instance, the shield
is to be terminated at one (1) end only. This recommendation
is based on considerations of signal degradation and noise
immunity in typical industrial environments as described in
Design, installation, and commissioning guidelines for
industrial control systems. For more information, refer to
Comments
Signatures / Date
Customer
Rolls-Royce
172
Completed Witnessed
3) Some control cables use a Mylar wrap for noise reduction

purposes that separate the shielded wire pairs. To eliminate
any ground problems due to the Mylar wrap separating, it is
recommended that heat shrink-wrap be used throughout the
field wiring termination process. Each individual shield, with
each pair, should have a smaller size heat shrink tube
4) The shield should not come in contact with other shields.
5) The shield should cover to within two (2) inches (5 cm) of
the termination point.
6) All cores to be identified and tagged in accordance with
the drawings, and +/- polarities to be labeled where critical.
7) All earth cores are to be coloured green/yellow or sleeved
green/yellow at termination points.
8) All screen drain wires are to be insulated with green heat
shrink, and all screens shown not connected at devices must
be insulated and tied back.
9) Instrument and IS grounding cables must have continuity
from the field device to the panel where the respective
ground connection is only in the panel.
10) All cable glands and conduit connectors are to be fitted
with locknuts, sealing washers, serrated washers and earth
tags as required except when terminating at EXD or EEXD
certified equipment where sealing washers are not permitted,
and serrated washers are not required.
11) Coat all cable gland threads with copper anti-seize before
installation.
Comments
Signatures / Date
Customer
Rolls-Royce
173
Completed Witnessed
12) All cable glands terminating at untapped gland plates in

the field are to be fitted with hubs instead of lock nuts.
13) The spare cables should be identified by tags, coiled up
and then stored underneath the cabinet. Terminated and
spare wire pairs should be treated in the same manner as
outlined in the procedure and linked to earth at the control
system.
14) Earthing and bonding to be carried out in accordance
with the above listed engineering standards. For more
information, refer to chapter "Engineering Standards, Forms,
and Drawings."
Installation Activities
Electrical, Control and Communication Cable Grouping from
Unit Control Panel (UCP) to:
1. AC Power Distribution
2. DC Power Distribution
3. Generator Control and Protection Panel
4. Electric Starter Controller Panel
5. Motor Control Center
6. Selective Catalytic Reduction / Continuous Emission
Monitoring System Panel
7. Variable Frequency Drives
8. Gas Fuel Metering Valve Controller
9. Liquid Fuel Metering Valve Controller
10. Inlet Spray Intercooler Skid
Comments
Signatures / Date
Customer
Rolls-Royce
174
Completed Witnessed
11. Liquid Fuel Skid

12. Water Injection Skid
13. Gas Turbine Enclosure
14. Generator Monitoring Panel
15. Generator Lube Oil Skid
16. Air Inlet Filter House Panel
17. Fire and Gas LON, Devices Power Supply and Customer
Interface
18. Human Machine Interface (HMI)
19. Control Net, Device Net and Eithernet Communication
Interface
Instructions:
1) Use proper tag out procedures when necessary to prevent
harm or damage to equipment and/or personnel.
2) Ensure that no AC or DC Voltages are present on
terminals or wiring before beginning work.
3) Ensure the cable to the field device is properly installed in
accordance with the above drawings and standards.
Note: Ensure all conductors and screens at both ends of
the interconnect cable are disconnected.
Safety Note: Damage to the control system or a sensor
is possible if all conductors are not disconnected!
4) With a 500V(1000v for 480v circuits)(1000v for 480v)
Megger verify all conductors of site installed instrument
Comments
Signatures / Date
Customer
Rolls-Royce
175
Completed Witnessed
cables have an infinite resistance to ground, and to each

other. (Do not exceed the voltage rating of the cable.)
5) Label and terminate both ends of the cable.
6) Verify with a digital multi meter that continuity exists from
the proper terminals in the control system to the end device.
7) Verify with a digital multi meter that no cores are grounded
unless shown grounded on the wiring diagrams.
8) Verify all grounds and screens are properly identified,
insulated, and terminated.
9) Correct any interconnect wiring errors, and re-label as
necessary, and note in the space provided below.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
176
Completed Witnessed
Activity 47 - Generator Control

Protection Panel (GCPP) Electrical,
Control and Communication Cables
Interconnect
Reference Documents
Siemens installation literature
Application
Vendor Literature
Siemens
Comments
Signatures / Date
Customer
Rolls-Royce
177
Completed Witnessed
Generator Circuit Breaker ( Supplied by Others )

Installation Notes
buzzer can be placed between the "clean" and "dirty"
ground bars. If the buzzer rings, that would indicate a
ground fault. It could be much easier to find a fault early in
the installation and commissioning process than at the end.
After the installation is complete, remove the buzzer.
terminated in the field. However, in either instance, the
shield is to be terminated at one (1) end only. This
recommendation is based on considerations of signal
degradation and noise immunity in typical
installation, and commissioning guidelines for industrial
reduction purposes that separate the shielded wire pairs.
To eliminate any ground problems due to the Mylar wrap
Comments
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Customer
Rolls-Royce
178
Completed Witnessed
separating, it is recommended that heat shrink-wrap be

used throughout the field wiring termination process. Each
individual shield, with each pair, should have a smaller size
heat shrink tube installed on it prior to termination.
5) The shield should cover to within two (2) inches (5 cm)
of the termination point.
shrink, and all screens shown not connected at devices
must be insulated and tied back.
certified equipment where sealing washers are not
permitted, and serrated washers are not required.
13) The spare cables should be identified by tags, coiled
up and then stored underneath the cabinet. Terminated
Comments
Signatures / Date
Customer
Rolls-Royce
179
Completed Witnessed
and spare wire pairs should be treated in the same manner

as outlined in the procedure and linked to earth at the
control system.
Electrical, Control and Communication Cable Grouping
from Generator Control Protection Panel (GCPP) to:
3. Unit Control Panel (UCP)
4. Generator Line and Neutral Junction Boxes
5. Generator Exciter
6. HV Switchgear
7. Customer Potential Transformer for Synchronizing
Instructions:
1) Use proper tag out procedures when necessary to
prevent harm or damage to equipment and/or personnel.
3) Ensure the cable to the field device is properly installed
in accordance with the above drawings and standards.
Comments
Signatures / Date
Customer
Rolls-Royce
180
Completed Witnessed

the proper terminals in the control system to the end
device.
7) Verify with a digital multi meter that no cores are
grounded unless shown grounded on the wiring diagrams.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
181
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
182
Completed Witnessed
Activity 48 - VFD for Water Injection (3),

Inlet Spray Intercooler (3), Water Flush
(1) Communication / Electrical
Interconnect
Reference Documents
Vendor Literature
Allen-Bradley Power Flex 70
Allen-Bradley Power Flex 700
Application
Installation Notes
Comments
Signatures / Date
Customer
Rolls-Royce
183
Completed Witnessed

degradation and noise immunity in typical industrial
environments as described in Design, installation, and
commissioning guidelines for industrial control systems.
Comments
Signatures / Date
Customer
Rolls-Royce
184
Completed Witnessed

control system.
Comments
Signatures / Date
Customer
Rolls-Royce
185
Completed Witnessed

15) For many VFD installations, unshielded power cable to
motor is adequate, provided it can be separated from
sensitive circuits. As an approximate guide, allow a
spacing of 0.3 meters (1 foot) for every 10 meters (32.8
feet) of length. In all cases, long parallel runs must be
avoided. Do not use cable with an insulation thickness less
than or equal to 15 mils (0.4mm/0.015 in.). Use Copper
wire only. Wire gauge requirements and recommendations
are based on 75° C. Do not reduce wire gauge when using
higher temperature wire. See vendor literature for details.
from Variable Frequency Drive (VFD) to each respective
motor and control:
2. Water Flush (1)
3. ISI Fogging and Water Injection Motors (3)
4. Water Injection Motors (3)
Instructions:
Comments
Signatures / Date
Customer
Rolls-Royce
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Completed Witnessed

device.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
187
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
188
Completed Witnessed
Activity 49 - Engine Starter Controller

Panel Electrical, Control and
Communication Cables Interconnect
Reference Documents
GED00187271 - Auxiliary Electrical Equipment
Vendor Manual
Doc No. 1003795 Ultra Electronics, Handbook For The
Electric Start System For The Industrial Trent 60 and
RB211 Gas Turbines
Application
Installation Notes
Comments
Signatures / Date
Customer
Rolls-Royce
189
Completed Witnessed
Note: Any wires that are damaged, must be repaired or

replaced according to the requirements outlined in Rolls-
Instrument Cables
Comments
Signatures / Date
Customer
Rolls-Royce
190
Completed Witnessed

control system.
Comments
Signatures / Date
Customer
Rolls-Royce
191
Completed Witnessed
14) The power cable from control panel to junction box

must be LAPP cable type OLFLEX® SERVO 9YSLCY-
JB 0037026 or equivalent.
15) The power cable must have a maximum length of 100
m between the ESC and ESM Junction Box.
from Electric Starter Controller Panel (ESC) to:
5. Electric Start Motor Junction Box
Instructions:
Comments
Signatures / Date
Customer
Rolls-Royce
192
Completed Witnessed

device.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
193
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
194
Completed Witnessed
Activity 50 - Motor Control Center

Communication and Electrical
Interconnect
Reference Documents
Customer Drawing:
Applicable Motor Control Center
Application
Comments
Signatures / Date
Customer
Rolls-Royce
195
Completed Witnessed
Installation Notes
All cables installed between the skid edge junction boxes
and the panels are to be megger tested before termination
in accordance with Rolls-Royce Engineering Standard
GEM 0047.
1) Thread all the previously installed instrumentation,
control and power cabling into the MCC and gland off.
Comments
Signatures / Date
Customer
Rolls-Royce
196
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
197
Completed Witnessed

control system.
from Motor Control Center (MCC) to:
5. Variable Frequency Drives
8. Human Machine Interface (HMI)
9. Control Net, Device Net and Eithernet Communication
Interface
Comments
Signatures / Date
Customer
Rolls-Royce
198
Completed Witnessed
Activity 51 - Control Panel Bonding,

Safety and Instrument (Signal) Ground
Reference Documents
Schematic
GED00179138 - Air Filter Wiring Diagram
GED00226674 - Air Inlet Filter House Panel Layout
Application

Control Cable Ground Shield
Comments
Signatures / Date
Customer
Rolls-Royce
199
Completed Witnessed

shields.
where critical.
Comments
Signatures / Date
Customer
Rolls-Royce
200
Completed Witnessed

Safety ground
All devices and/or equipment shall be installed using
the equipment manufacturers' grounding and bonding
requirements. Special attention must be paid to safety
grounds, wherever possible a double safety ground
from two (2) different points of the device and/or
equipment, to two (2) different ground points should be
used.
All grounds shall be made using techniques and
cabling as defined by the electrical code of the country
into which the equipment is to be installed. At a
minimum, GER 0070 - Grounding / Earthing Design
and Application should be followed.
Signal ground
Signal grounds are segregated from safety ground.
The Unit Control Panel is fitted with two ground bus
for Safety and Signal Ground. Special care must be
taken to isolate all ground systems from each other,
only connecting the grounding systems together as
defined by the equipment manufacturer. This can be a
particular problem if IS (Intrinsically Safe) barriers are
Comments
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Customer
Rolls-Royce
201
Completed Witnessed
used as these devices are invariably connected to

safety ground.
When IS barriers are used on an electrically isolated
(floating) system, they can create an inadvertent circuit
to ground, so compromising the isolated grounding
system.
Connection of grounding systems
Normal practice is to connect ground systems together
at a single point to avoid ground loops, which can
induce interference on signal lines caused by
circulating currents within the grounding systems,
particularly on signal shields.
Install panel bonding, safety and signal ground at:
1. Unit Control Panel
2. Generator Control and Protection Panel
6. Water Injection Skid
7. Liquid Fuel Skid
Comments
Signatures / Date
Customer
Rolls-Royce
202
Completed Witnessed
Activity 52 - Fire and Gas System

Interconnect
Reference Documents
GED00196976 - Fire & Gas Wiring
Application
Vendor Literature
Fire System vendor documentation
Comments
Signatures / Date
Customer
Rolls-Royce
203
Completed Witnessed
Installation Notes
Instrument Cables
Comments
Signatures / Date
Customer
Rolls-Royce
204
Completed Witnessed

control system.
Comments
Signatures / Date
Customer
Rolls-Royce
205
Completed Witnessed
Installation Activities:
1)Install the following shipped loose devices.
74FPEVGTH1 - Sounder
74FPEVGTB1 - Beacon
74FPEVGTH2 - Sounder
74FPEVGTB2 - Beacon
71GPEVGT01 - Gas Detector
71GPEVGT02 - Gas Detector
2)Run, gland and terminate the following cables.
E7100 - UCP to FPGT-1 Suppression Skid Interface
Terminals
E7101 - UCP to FPGT-3 Suppression Skid Interface
Terminals
E7102 - FPGT-3 Suppression Skid Interface Terminals to
FPGT-1 GT Enclosure Interface Terminals
E7019A - SAM Address 05 to 74FPEVGTB1 Beacon and
74FPEVGTH1 Sounder
E7016 - FPGT-1 GT Enclosure Interface Terminals to
74FPEVGTB2 Beacon and 74FPEVGTH2 Sounder
E7006 - FPGT-2 Junction Box to 71GPEVGT01 Gas
Detector
E7007 - 71GPEVGT01 - Gas Detector to 71GPEVGT02
Gas Detector
E7008 - 71GPEVGT02 - Gas Detector to FPGT-2 Junction
Box
Comments
Signatures / Date
Customer
Rolls-Royce
206
Completed Witnessed
3)Verify LON addresses are correctly set at DIP Switch:

Address 01 - LA_001_EQP Processor
Address 05 - SAM Signal Audio Module
Address 06 - 28FPEVGT1 GT Enclosure Oil Tank Flame
Detector 1
Address 07 - 28FPEVGT2 GT Enclosure Fuel Skid Flame
Detector 2
Address 08 - 28FPEVGT3 GT Enclosure Lower Flame
Detector 3
Address 09 - 71GPEGT01 Ventilation Outlet Gas Detector
1
Address 10 - 71GPEGT02 Ventilation Outlet Gas Detector
2
Address 11 - 28FPEVGT4 GT Enclosure Upper Flame
Detector 4
Address 12 - FPGT-1 GT Enclosure Interface Terminals
Address 51 - FPGT-3 Suppression Skid Interface Terminal
4)Follow termination details for device safety and
instrument ground as outlined in GED00017789 sheets 7
to 12 - Fire and Gas CO2 Interconnect and Wiring
Assembly
5) AC Power Distribution for CO2 Skid Heater
Instructions:
Comments
Signatures / Date
Customer
Rolls-Royce
207
Completed Witnessed

4) With a 500V(1000v for 480v circuits) Megger verify all
conductors of site installed instrument cables have an
infinite resistance to ground, and to each other. (Do not
exceed the voltage rating of the cable.)
device.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
208
Completed Witnessed
Activity 53 - CO2 Cabinet Bonding and

Equipment / F&G Devices Ground
Reference Documents
Schematic
Application
Control Cable Ground Shield
Comments
Signatures / Date
Customer
Rolls-Royce
209
Completed Witnessed

shields.
Safety ground
Comments
Signatures / Date
Customer
Rolls-Royce
210
Completed Witnessed
All devices and/or equipment shall be installed using

the equipment manufacturers' grounding and bonding
requirements. Special attention must be paid to safety
grounds, wherever possible a double safety ground
from two (2) different points of the equipment, to two (2)
different ground points should be used.
All grounds shall be made using techniques and
cabling as defined by the electrical code of the country
into which the equipment is to be installed. At a
minimum, GER 0070 - Grounding / Earthing Design
and Application should be followed.
Signal ground
Signal grounds are segregated from safety ground. The
Unit Control Panel is fitted with two ground bus for
Safety and Signal Ground. Special care must be taken
to isolate all ground systems from each other, only
connecting the grounding systems together as defined
by the equipment manufacturer. This can be a
particular problem if IS (Intrinsically Safe) barriers are
used as these devices are invariably connected to
safety ground.
When IS barriers are used on an electrically isolated
(floating) system, they can create an inadvertent circuit
to ground, so compromising the isolated grounding
system.
Connection of grounding systems
Comments
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Customer
Rolls-Royce
211
Completed Witnessed
Normal practice is to connect ground systems together

at a single point to avoid ground loops, which can
induce interference on signal lines caused by
circulating currents within the grounding systems,
particularly on signal shields.
Install panel bonding, safety and signal ground at:
1. CO2 Cabinet and Junction Box
2. Shipped Loose Field Devices
Field Devices have interconnected safety and signal
ground. See GED00017789 Sheet 7 to 12 for
connection details.
Comments
Signatures / Date
Customer
Rolls-Royce
212
Completed Witnessed
Activity 54 - Gas Turbine Ventilation

Fan Motor (3) Electrical Interconnect
Reference Documents
GED00207859 - Gas Turbine Ventilation System
Diagram
Customer Drawing:
Application
Comments
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Customer
Rolls-Royce
213
Completed Witnessed
Vendor Literature:
Installation
prevent harm or damage to equipment and/or
personnel.
3) Ensure the cable to the motor is properly
installed in accordance with the above drawings and
standards.
4) With a 1000V Megger verify all conductors have an
infinite resistance to ground, and to each other.
5) Label and terminate both ends of power cable.
6) Label and terminate motor space heater cable.
7) Label and terminate Stop Pushbutton cable.
Comments
Signatures / Date
Customer
Rolls-Royce
214
Completed Witnessed
8) Verify with a digital multi meter that continuity exists

from the proper terminals in the control system to the
end device.
grounded unless shown grounded on the wiring
diagrams.
10) Verify all grounds and screens are properly
identified, insulated, and terminated.
11) Correct any interconnect wiring errors, and re-label
as necessary, and note in the space provided below.
Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
215
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
216
Completed Witnessed
Activity 55 - GT Enclosure Ventilation

Fire Damper (2) Control Interconnect
Reference Documents
Schematic
GED00196976 - Fire and Gas System
Application
Vendor Literature:
Comments
Signatures / Date
Customer
Rolls-Royce
217
Completed Witnessed

Installation
personnel.
2) Ensure that no DC Voltages are present on
3) Ensure the cable to the solenoid and position
switches are properly installed in accordance with the
above drawings and standards.
4) With a 500V(1000v for 480v circuits) Megger verify
all conductors have an infinite resistance to ground,
and to each other.
5) Label and terminate both ends of cable for solenoid
and limit switch.
rom the proper terminals in the control system to the
end device.
Comments
Signatures / Date
Customer
Rolls-Royce
218
Completed Witnessed

diagrams.
Problems and Notes
10) Connect pneumatic tubing from CO2 header

and instrument air line.
Comments
Signatures / Date
Customer
Rolls-Royce
219
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
220
Completed Witnessed
Activity 56 - GT Enclosure Installation of

Electrical Ship Loose Items and
Interconnect
Reference Documents
Application
Install and interconnect the following GT Enclosure electrical
devices:
Comments
Signatures / Date
Customer
Rolls-Royce
221
Completed Witnessed
1) GT Enclosure Space Heater to AC Power Distribution

Instructions:
1) Use proper tag out procedures when necessary to prevent
harm or damage to equipment and/or personnel.
3) Ensure the cable to the field device is properly installed in
conductors of site installed instrument cables have an infinite
resistance to ground, and to each other. (Do not exceed the
voltage rating of the cable.)
the proper terminals in the control system to the end device.
7) Verify with a digital multi meter that no cores are grounded
unless shown grounded on the wiring diagrams.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
222
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
223
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
224
Completed Witnessed
Activity 57 - Engine Starter Electrical /

Control Interconnect
Reference Documents
Vendor Manual
Doc No. 1003795 Ultra Electronics, Handbook For The
Electric Start System For The Industrial Trent 60 and
RB211 Gas Turbines
Application
Installation Note
1) Use Doc No. 1003795 Ultra Electronics, Handbook For
The Electric Start System For The Industrial Trent 60 and
RB211 Gas Turbines when terminating power and
instrument cables on electric start motor.
2) The weight of the electric start motor is 244 Lbs (111
Kg).
3) ESM Power Cables are subject to a minimum bend
radius of ten times the outside diameter of the cable.
Comments
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Customer
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Completed Witnessed
4) An installation kit is supplied with the Electric Starter

Motor. The installation kit allows the customer to electrically
configure the motor in a Star or Delta arrangement
dependant upon the motor’s application. The star shaped
link allows the motor terminal studs to be connected in Star
configuration. The rectangular delta links allows the motor
terminal studs to be connected in a Delta configuration.
Electric Starter Motor for Industrial Trent 60 must be
connected to Star arrangement.
Procedure
To install the ESM with the ESM connections in a star
configuration proceed as follows:
CAUTION EQUIPMENT DAMAGE: When connecting the
ESM power cable to the motor terminals, ensure that
new Tab washers are always used.
(1) To configure the ESM connections in a star
configuration proceed as follows:
a. From the installation kit, obtain the Star Link to secure to
the terminal studs as detailed in the following steps.
b. From the installation kit, obtain the Terminal Assembly
Aid E00002759. This will be used to determine the height
of the Star Link connections. Attach to rear of the motor
adjacent to terminal U2 (Fig 1).
c. From the installation kit, fit a single terminal nut to the
terminal marked U2 (Fig 1) running the nut down until it
touches the Terminal Assembly Aid. Repeat the process
for terminals V2 and W2.
Comments
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Customer
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Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
227
Completed Witnessed
d. Fit an unused tab washer (Fig 1) from the installation kit

to the terminals marked U2, V2 and W2.
e. Fit the star link to the terminals marked U2, V2 and W2
(Fig 1).
f. Fit an unused tab washer from the installation kit over
the terminals marked U2, V2 and W2.
g.Fit the remaining terminal nuts to the terminals
marked U2, V2 and W2.
CAUTION EQUIPMENT DAMAGE. Do not over tighten
assembly as damage to the motor may occur.
h. Using a 19mm spanner hold the motor side nut station-
ary and tighten the other nut to a torque of 25Nm
(18.4lbf).
i. Using pliers fold one of the tabs on each washer
towards the star link.
j. Fold the remaining straight tab on each washer (Fig 2)
against its adjacent nut to prevent loosening of the
connection under vibration.
Comments
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Customer
Rolls-Royce
228
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
229
Completed Witnessed
WARNING EXCESSIVE WEIGHT. THE WEIGHT OF THE

ELECTRIC START MOTOR IS 111KG.
(2) Using a suitable lifting device offer the ESM to the installa-
tion site.
CAUTION EQUIPMENT DAMAGE. The secondary support
fixture must ONLY be used as a means of levelling the
ESM position. It is not designed to take the full weight of
the ESM. The M8 lifting eyebolt must ALWAYS be used for
lifting the ESM.
Note: An M8 eyebolt fitted to the top of the ESM is provided
as a lifting aid. The ESM also has 4 handling feet fitted with
1/4-28-UNJF-3B Keensert helicoils which can be used in
conjunction with the eyebolt to move the ESM into position.
(3) Align the locating dowel fitted to the ESM pad face at 3
o’clock (when viewed from shaft end) with the hole in the
Gas Turbine pad face.
(4) Interface the end of the ESM rotor shaft with the Gas Tur-
bine using the locating dowel as an alignment aid.
(5) Secure the ESM to the Gas Turbine using a V band clamp.
(6) Remove the shipment blanking plugs from the oil inlet and
oil outlet ports.
(7) Connect the incoming oil supply pipe to the oil inlet port on
the top of the ESM as shown in Fig 3.
(8) Connect the oil outlet pipe to the oil drain port at the base
of the ESM as shown in Fig 3.
(9) Connect the oil breather pipe to the vent at the top of the
ESM as shown in Fig 3.
Comments
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Customer
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Completed Witnessed
(10) Before commencing any further work on the ESM instal-

lation, conduct an earth bonding test between the ESM
body and the installation site earth. Confirm that the
measured resistance is less than 5mΩ.
(11) Remove the cable gland nuts, washers and seals from
Comments
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Customer
Rolls-Royce
231
Completed Witnessed
the rear protective terminal cowl refer to Fig 10.

(12) Pass the ends of the two cables from the ESM power
cable assembly through the cable gland nuts, washers
and seals and through the two gland bosses in the rear
terminal cowl. Ensure that the cowl earth stud is oriented
at the bottom of the overall assembly.
(13) Cut the two power cables to length.
(14) Remove 370mm of insulation from the outer sheath of
each power cable to allow the inner cores (i.e. power
cores and earth cores) and screens to be made off. The
outer insulation should not be back further than the posi-
tions of the cable gland nuts when cowl is installed.
(15) On each power cable unravel cable screens and twist
strands together to form a single core for each power
cable.
(16) Cut inner cores to length in accordance with Table 1 and
Fig 4.
TABLE 1 INNER CORE LENGTHS FOR STAR CONNEC-
TION
Core Power Cable 1 Power Cable 2
Earth 370mm 370mm

Yellow/Green
(3 per)
Screens 360mm 360mm

(1 per)
Brown 260mm 260mm
Black 290mm 290mm
Grey 270mm 270mm
Comments
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Customer
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232
Completed Witnessed
Comments
Signatures / Date
Customer
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233
Completed Witnessed
(17) Remove sufficient insulation from the inner cores to

enable the crimp connections to be made without leaving
conductors exposed after crimping.
(18) Using the M12 crimps from the cable assembly kit make
off the crimp connections to the three power cores for
each of the two power cables.
(19) Using the M6 crimps from the cable assembly kit make
off the crimp connections for the three earth cores for
each of the two power cables and the screen for each of
the two power cables.
(20) Fit heatshrink sleeving over each power cable screen
and shrink onto screen.
CAUTIONS
(1) EQUIPMENT DAMAGE. ESM Power Cables are sub-
ject to a minimum bend radius of ten times the outside
diameter of the cable.
(2) EQUIPMENT DAMAGE. External means of sup-
porting the weight of the ESM power cables must
be provided.
(21) The two power cables to the ESM have a minimum bend
radius. For final assembly of the ESM there must be suf-
ficient length in both power cables to ensure the mini-
mum bend radius of the power cable is not
compromised.
(22) The power cables must be externally supported as close
to the ESM as possible. This is necessary to prevent
excessive loads being applied to the ESM cowl, terminal
pins and mounting flange.
CAUTIONS EQUIPMENT DAMAGE: When connecting
the ESM power cable to the motor terminals, ensure
that new Tab washers and Terminal Assembly Aid are
always used.
(23) Terminate the inner cores to the ESM terminals in accor-
dance with, Fig 6, Fig 32, the Cable Data Sheets pro-
Comments
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Customer
Rolls-Royce
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Completed Witnessed
vided in Table 5 and the following procedure:

a. From the installation kit, obtain the Terminal
Assembly Aid E00002759. This will be used to
determine the height of the core terminations.
b. From the installation kit, fit a single terminal nut to
the terminal marked U1 (Fig 5) running the nut
down until it touches the Terminal Assembly Aid.
Repeat the process for terminals V1 and W1.
c. Fit an unused tab washer (Fig 5) from the installa-
tion kit to the terminals marked U1, V1 and W1.
d. Fit an angle position washer (Fig 5) from the instal-
lation kit to the terminals marked U1, V1 and W1.
Comments
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Customer
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Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
236
Completed Witnessed
e. Fit two M12 crimped power cores to the terminals

marked U1, V1 and W1, Refer to Fig 6.
NOTE
There are three connections to G1, three connections to G2
and two connections to G3.
CAUTION EQUIPMENT DAMAGE. Ensure the M12 crimped
power cores are fitted using the installation aid. If fitted
incorrectly shorting to the cowl may occur.
f. Using the Terminal Assembly Aid locate the Angle
Position washer and power core crimp bodies as
indicated in Fig 7.
CAUTION EQUIPMENT DAMAGE. Ensure there is a mini-
Comments
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Customer
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Completed Witnessed
mum clearance of 13mm between adjacent

terminals as shorting between terminals may occur.
g. Ensure there is minimum clearance of 13mm
between adjacent terminals (Fig 7).
Comments
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Customer
Rolls-Royce
238
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
239
Completed Witnessed
h. Fit an unused tab washer from the installation kit

over the terminals marked U1, V1 and W1.
i. Fit the remaining terminal nuts to the terminals
marked U1, V1 and W1, tightening finger tight
until no clearance remains in the bolted connec-
tions.
j. Using a 19 mm spanner hold the motor side nut sta-
tionary and tighten the other nut to a torque of 25
Nm (18.4 lbf).
k. Using pliers fold one of the tabs on each washer
towards the star link.
CAUTION EQUIPMENT DAMAGE. Do not over tighten
assembly as damage to the motor may occur.
l. Fold the remaining straight tab on each washer
against its adjacent nut to prevent loosening of
the connection under vibration.
m. For power cable 1 fit three M6 crimped earth cores
to earth location G1 (refer to Fig 6) and secure
using an M6 bolt, angle position washer and plain
washer. Ensure crimp positioning washer is located
correctly as shown in Fig 8.
n. For power cable 2 fit three M6 crimped earth cores
to earth location G2 (refer to Fig 6) and secure
using an M6 bolt, angle position washer and plain
washer. Ensure crimp positioning washer is located
correctly as shown in Fig 8.
o. For power cables 1 and 2 fit two M6 crimped earth
screen to earth location G3 (refer to Fig 6, Fig 32
and the Cable Data Sheets provided in Table 5) and
secure using an M6 bolt, angle position washer,
plain washer and spring washer. Ensure crimp posi-
tioning washer is located correctly as shown in Fig
8.
p. Ensure that each earth core crimp body is facing in
Comments
Signatures / Date
Customer
Rolls-Royce
240
Completed Witnessed
the direction indicated in Fig 7.

CAUTION EQUIPMENT DAMAGE. Ensure there is a mini-
mum clearance of 13 mm between adjacent terminals as
shorting between terminals may occur.
q. Ensure there is minimum clearance of 13 mm
between adjacent terminals as shown in Fig 7.
r. Using a 10 mm spanner tighten the M6 bolt
secure 3 earth core crimps from power cable 1
to G1, 3 earth core crimps from power cable 2 to G2
and the 2 earth screens to G3 to a torque of 15.0
Nm (11.1 lbf).
Comments
Signatures / Date
Customer
Rolls-Royce
241
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
242
Completed Witnessed
(24) Connect the interface cable to the signal connector on

the top of the ESM, refer to Fig 9.
Comments
Signatures / Date
Customer
Rolls-Royce
243
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
244
Completed Witnessed
(25) Before fitting the cowl, ensure that sufficient power cable
length is retained to reach the ESM and to maintain the
correct cable bend radius.
CAUTIONS EQUIPMENT DAMAGE. ESM Power Cables are
subject to a minimum bend radius of
ten times the outside diameter of the cable. External
means of supporting the weight of the ESM power
cables must be provided.
(26) Use the six M6 socket head cap screws with washers
from the installation kit to secure the cowl to the ESM.
(27) Fit cable gland seal, washer and gland nut. Tighten
gland nut to fully seal the power cables.
28) Remove the earth cable (for cowl to ESM body) and M10
crimps from the installation kit.
(29) Remove sufficient insulation from each end of the earth
cable to enable the M10 crimp connections to be made
without leaving conductors exposed after crimping.
(30) Using the M10 crimps from the installation kit make off
the crimp connections to each end of the earth cable.
(31) Connect one end of the earth cable to the cowl earth
stud using M10 nut, plain washer and spring washer.
(32) Confirm that the measured resistance between the
ESM body and the cowl is less than 5mΩ.
Comments
Signatures / Date
Customer
Rolls-Royce
245
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
246
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
247
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
248
Completed Witnessed
Activity 58 - GT Instrument / Control

Interconnect
Reference Documents
Application
Comments
Signatures / Date
Customer
Rolls-Royce
249
Completed Witnessed
Electrical, Control
1) GT AC Powered Lighting
2) GT DC Emergency Lighting
Instructions:
personnel.
3) Ensure the cable to the field device is properly
standards.
all conductors of site installed instrument cables have
an infinite resistance to ground, and to each other. (Do
not exceed the voltage rating of the cable.)
Comments
Signatures / Date
Customer
Rolls-Royce
250
Completed Witnessed

end device.
diagrams.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
251
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
252
Completed Witnessed
Activity 59 - Gas Fuel Metering Valves

Controller Interconnect
Reference Documents
Schematic
Application
Comments
Signatures / Date
Customer
Rolls-Royce
253
Completed Witnessed

Installation
ground fault. It could be much easier to find a fault early
in the installation and commissioning process than at
the end. After the installation is complete, remove the
buzzer.
Comments
Signatures / Date
Customer
Rolls-Royce
254
Completed Witnessed

shields.
where critical.
10) All cable glands and conduit connectors are to be
fitted with locknuts, sealing washers, serrated washers
and earth tags as required except when terminating at
Comments
Signatures / Date
Customer
Rolls-Royce
255
Completed Witnessed
EXD or EEXD certified equipment where sealing

washers are not permitted, and serrated washers are
not required.
12) All cable glands terminating at untapped gland
plates in the field are to be fitted with hubs instead of
lock nuts.
13) The spare cables should be identified by tags,
coiled up and then stored underneath the cabinet.
Terminated and spare wire pairs should be treated in
the same manner as outlined in the procedure and
linked to earth at the control system.
14) Earthing and bonding to be carried out in
accordance with the above listed engineering
standards. For more information, refer to chapter
from Gas(EMV1) and Liquid(EMV2) Fuel Metering
Valve Controllers to Unit Control Panel for the following
cables:
1) 75FGMC (communications)
2) 75FGME (control)
3) 86FGM (control)
Comments
Signatures / Date
Customer
Rolls-Royce
256
Completed Witnessed
4) 90FGM (power)
5) 75FL1ME (control)
6) 86FL1M (control)
7) 90FL1M (power)
Instructions:
personnel.
3) Ensure the cable to the field device is properly
standards.
5) Label and terminate both ends of the cables.
Comments
Signatures / Date
Customer
Rolls-Royce
257
Completed Witnessed

end device.
diagrams.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
258
Completed Witnessed
Activity 60 - Gas Turbine Hydraulic Oil

Pump Motor (2) Electrical Interconnect
Reference Documents
Customer Drawing:
Application
Vendor Literature:
Comments
Signatures / Date
Customer
Rolls-Royce
259
Completed Witnessed
Installation
3) Ensure the cable to the motor is properly installed in
4) With a 1000V Megger verify all conductors have an
infinite resistance to ground, and to each other.
device.
Comments
Signatures / Date
Customer
Rolls-Royce
260
Completed Witnessed
Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
261
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
262
Completed Witnessed
Activity 61 - GT Lube Oil Reservoir

Heater Electrical Interconnect
Reference Documents
GED00221307 - Cable Routing
GED00219251 - GT Lube Oil Skid Outline
Customer Drawing:
Application
Vendor Literature:
Comments
Signatures / Date
Customer
Rolls-Royce
263
Completed Witnessed

Installation
3) Ensure the cable to the heater is properly installed in
Safety Note: Safety Note: Damage to the control sys-
tem or a sensor is possible if all conductors are not
disconnected!
conductors have an infinite resistance to ground, and to
each other.
6) Label and terminate thermostat cable.
device.
Comments
Signatures / Date
Customer
Rolls-Royce
264
Completed Witnessed

Problems and Notes
Instructions:
device.
Comments
Signatures / Date
Customer
Rolls-Royce
265
Completed Witnessed

Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
266
Completed Witnessed
Activity 62 - ASC Secondary Air Fan

Electrical Interconnect
Reference Documents
GED00207859 - Gas Turbine Ventilation System Diagram
Customer Drawing:
Application
Vendor Literature:
Comments
Signatures / Date
Customer
Rolls-Royce
267
Completed Witnessed
Installation
each other.
device.
Comments
Signatures / Date
Customer
Rolls-Royce
268
Completed Witnessed
Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
269
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
270
Completed Witnessed
Activity 63 - Air Filter Inlet House / Pulse

Air Control Panel Electrical Interconnect
Reference Documents
GED00226679 - AIFH Electrical Installation
GED00226674 - Air Inlet Filter House Panel Layout
Application
Comments
Signatures / Date
Customer
Rolls-Royce
271
Completed Witnessed

Installation
Comments
Signatures / Date
Customer
Rolls-Royce
272
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
273
Completed Witnessed

control system.
from Air Filter Inlet House / Pulse Air Control Panel to:
1. AC Power Distribution (120V)
2. DC Power Distribution from UCP (24vdc)
3. Control Net Communication (Controlnet 2) as per site
communications configuration.
4. Unit Control Panel (UCP) Instrument Ground
Instructions:
Comments
Signatures / Date
Customer
Rolls-Royce
274
Completed Witnessed

device.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
275
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
276
Completed Witnessed
Activity 64 - Gas Turbine / Generator

and Enclosure Bonding and Grounding
Reference Documents
GER 0070 - Earthing Design and Application
Generator vendor documentation
Instructions Notes
Any wires that are damaged, must be repaired or
replaced according to the requirements outlined in
Rolls-Royce Engineering Standard GEM 0111. For
more information, refer to chapter "Engineering
1) When verifying and inspecting the grounding system,
ensure the grounding conductors to the site ground grid
are of sufficient size to meet local electrical codes.
2) Ensure all bonding cables are the same size of
larger and all cables are either green or yellow/green as
specified in the above listed drawings.
3) Ensure all main connection use dielectric grease or
an enhancing product to help prevent corrosion and
improve ground the connection.
Comments
Signatures / Date
Customer
Rolls-Royce
277
Completed Witnessed
4) Review the site ground layout. Procure a copy of the

site grounding system test and attach it to this
procedure in the ICS Manuals for all units.
5) Review the equipment in the list below and verify
that all of the parts are properly bonded to the site
earthing system as per the above listed drawings.
a) Verify all the gas turbine (GT) base is bonded to the
site earth ground.
b) Verify all the AC generator base is bonded to the site
earth ground.
c) Verify all of the GT enclosure parts are bonded to
each other and to the site earth ground.
d) Verify all of the AC enclosure parts are bonded to
each other and to the site earth ground.
e) Verify all of the AAF air filter ducting on the GT skid
is bonded together and to the site earth ground.
f) Verify all of the attached air ducting on the AC
generator skid is bonded together and to the site earth
ground.
g) Verify all of the gas piping is bonded to the site
ground and across any flange points.
6) List any problems or notes of interest in the space
provided below.
Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
278
Completed Witnessed
Activity 65 - Generator Space Heater

Temporary Power
Reference Documents
Generator Vendor Literature
Connect temporary 480 volt power supply for
Generator Space Heaters at JB19
Instructions:
personnel.
3) Ensure the cable to the following generator space
heaters are properly installed in accordance with the
above drawings and standards:
Comments
Signatures / Date
Customer
Rolls-Royce
279
Completed Witnessed
95GNS-R1
95GNS-R2
5) Connect temporary 480 volt 3 phase power supply to
generator space heaters.
6) Verify proper current flow in all three phases.
7) Install proper warning signs to notify personnel of
electrical hazard.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
280
Completed Witnessed
Activity 66 - Generator Exciter End

Enclosure Electrical Interconnect
Reference Documents
Application
Vendor Literature
Siemens
Generator Circuit Breaker ( Supplied by Others )
Installation Notes
Comments
Signatures / Date
Customer
Rolls-Royce
281
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
282
Completed Witnessed

control system.
Comments
Signatures / Date
Customer
Rolls-Royce
283
Completed Witnessed

from Generator Exciter End Enclosure (JB19) to:
1. AC Power Distribution (480v generator space heater,
120v for heaters, lighting, and DAC)
3. Generator Control and Protection Panel (GCPP)
4. Generator Line and Neutral Junction Boxes (Heater
Supply)
Instructions:
Comments
Signatures / Date
Customer
Rolls-Royce
284
Completed Witnessed

device.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
285
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
286
Completed Witnessed
Activity 67 - Generator Monitoring Panel

Reference Documents
GED00160539 - Generator Monitoring Panel
GED00221298 - AC Generator Lube Oil Electrical
Drawings
Application
Comments
Signatures / Date
Customer
Rolls-Royce
287
Completed Witnessed

Installation Notes
Comments
Signatures / Date
Customer
Rolls-Royce
288
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
289
Completed Witnessed

control system.
from Generator Monitoring Panel to each respective
device:
1. DC Power Distribution Unit Control Panel (UCP)
2. Generator Lube Oil Console Junction Box
3. Control Net Communication (Controlnet 2) as per site
communications configuration.
4. DAC control panel JB21(Han type connectors)
5. Instrument Ground (UCP)
Instructions:
Note: Note: Ensure all conductors and screens at both
ends of the interconnect cable are disconnected.
Comments
Signatures / Date
Customer
Rolls-Royce
290
Completed Witnessed

device.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
291
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
292
Completed Witnessed
Activity 68 - Generator HV Electrical

Interconnect
Reference Documents
GED00242840 - Siemens Installation Manual
GED00235373 - HV Single Line Diagram
Application
Install HV cable system to HV switchgear in accordance
with Siemens Installation Manual and local site
requirements.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
293
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
294
Completed Witnessed
Activity 69 - Generator Instrument /

Control Cable Interconnect
Reference Documents
GED00230718 - AC Generator General Aggangement
Application
Vendor Literature
Siemens
Comments
Signatures / Date
Customer
Rolls-Royce
295
Completed Witnessed

Installation Notes
Comments
Signatures / Date
Customer
Rolls-Royce
296
Completed Witnessed

must
Comments
Signatures / Date
Customer
Rolls-Royce
297
Completed Witnessed

control system.
Electrical and Control Cable Grouping from Generator
Instrument and Control Interconnect to the following
devices:
1. Emergency Stop Pushbutton 86GN1(Mounted on Line
Cubicle) to Unit Control Panel (UCP)
2. Emergency Stop Pushbutton 86GN2 (Mounted on
Neutral Cubicle) to Unit Control Panel (UCP)
Instructions:
Comments
Signatures / Date
Customer
Rolls-Royce
298
Completed Witnessed

device.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
299
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
300
Completed Witnessed
Activity 70 - Generator Current and

Potential Transformer Electrical
Interconnect
Reference Documents
GED00168530 - AC Generator Monitoring Panel General
Arrangement
GED00235373 - HV Single Line Generator Diagram
GED00234373 - Neutral Cubicle General Arrangement
GED00234372 - Line Cubicle General Arrangement
Application
Vendor Literature
Comments
Signatures / Date
Customer
Rolls-Royce
301
Completed Witnessed
Siemens
Installation Notes
Current and Potential Transformers Junction Box JB11
Neutral Cubicle and JB14 Line Cubicle to:
1. Generator Control and Protection Panel (GCPP)
2. Customer Synchronizing Panel
Instructions:
in accord
Comments
Signatures / Date
Customer
Rolls-Royce
302
Completed Witnessed

device.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
303
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
304
Completed Witnessed
Activity 71 - Generator Lube Oil

Auxiliary Pump Electrical Interconnect
Reference Documents
GED00221298 - AC Generator Lube Oil Electrical
Drawings
GED00207460 - Generator Lube Oil Skid Outline
GED00238346 - Generator Lube Oil Console Electrical
Drawings
Customer Drawing:
Application
Comments
Signatures / Date
Customer
Rolls-Royce
305
Completed Witnessed

Vendor Literature:
Installation
Ensure the cable to the motor is properly installed in
Safety Note: Safety Note: Damage to the control sys-
tem or a sensor is possible if all conductors are not
disconnected!
each other.
device.
Comments
Signatures / Date
Customer
Rolls-Royce
306
Completed Witnessed

Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
307
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
308
Completed Witnessed
Activity 72 - Generator Jacking Oil Pump

Reference Documents
GED00226332 - Generator Lube Oil Electrical
Drawings - Mitten
GED00226333 - Generator Lube Oil Skid Outline -
Mitten
Customer Drawing:
Application
Comments
Signatures / Date
Customer
Rolls-Royce
309
Completed Witnessed

Vendor Literature:
Installation
personnel.
and to each other.
Comments
Signatures / Date
Customer
Rolls-Royce
310
Completed Witnessed

end device.
diagrams.
Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
311
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
312
Completed Witnessed
Activity 73 - Generator Emergency Lube

Oil Pump ( DC ) Electrical Interconnect
Reference Documents
Drawings - Mitten
Mitten
Customer Drawing:
Application
Comments
Signatures / Date
Customer
Rolls-Royce
313
Completed Witnessed

Vendor Literature:
Installation
personnel.
and to each other.
Comments
Signatures / Date
Customer
Rolls-Royce
314
Completed Witnessed

end device.
diagrams.
Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
315
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
316
Completed Witnessed
Activity 74 - Generator Lube Oil Dimister

Motor Electrical Interconnect
Reference Documents
Drawings - Mitten
Mitten
Customer Drawing:
Application
Comments
Signatures / Date
Customer
Rolls-Royce
317
Completed Witnessed
Vendor Literature:
Installation
each other.
device.
Comments
Signatures / Date
Customer
Rolls-Royce
318
Completed Witnessed

Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
319
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
320
Completed Witnessed
Activity 75 - Generator Lube Oil Heater

Reference Documents
Drawings - Mitten
Mitten
Customer Drawing:
Application
Comments
Signatures / Date
Customer
Rolls-Royce
321
Completed Witnessed
Vendor Literature:
Installation
3) Ensure the cable to the heater is properly installed in
each other.
6) Label and terminate thermostat cable.
device.
Comments
Signatures / Date
Customer
Rolls-Royce
322
Completed Witnessed

Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
323
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
324
Completed Witnessed
Activity 76 - Generator Lube Oil Skid

Instrument / Control Interconnect
Reference Documents
GED00226332 - Generator Lube Oil Electrical Drawings -
Mitten
GED00226333 - Generator Lube Oil Skid Outline - Mitten
Vendor Literature
Application
Comments
Signatures / Date
Customer
Rolls-Royce
325
Completed Witnessed

Installation Notes
Comments
Signatures / Date
Customer
Rolls-Royce
326
Completed Witnessed

Comments
Signatures / Date
Customer
Rolls-Royce
327
Completed Witnessed

control system.
Lube Oil Skid Junction Box to each respective device:
1. Unit Control Panel (UCP) Main Lube Oil Pressure
Regulator Valve
2. Generator Monitoring Panel (GMP)
Instructions:
Comments
Signatures / Date
Customer
Rolls-Royce
328
Completed Witnessed

device.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
329
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
330
Completed Witnessed
Activity 77 - Set up of HMI (FT210)

Servers and communications
Reference Documents
Customer Drawing:
PDC Building Layout
Configure HMI FT210 communications server and work
station to serve as temporary control room during
installation and commissioning activities.
Setup the following equipment provided by RR:
Desktop Monitor
FT210 5 Port Thin Client Computer U9 or U10
Keyboard and Mouse
Primary Server - MA371 Pri and/or Secondary Server -
MA371 Sec
Set up following temporary equipment:
UPS power supply
Comments
Signatures / Date
Customer
Rolls-Royce
331
Completed Witnessed
Ethernet Switch
Internal Ethernet Communications from FT210 work station
UCP
External Ethernet Communications to all other PDC's.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
332
Completed Witnessed
Activity 78 - Generator Insulation

Resistance Testing
Reference Documents
GEMF0047 - Cable Test Sheet
Generator vendor documentation
Perform insulation resistance checks on the following:
1. Generator Stator
2. Generator Rotor
3. Generator Exciter
4. Generator PMG
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
333
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
334
Chapter 4 Electrical activities
335
Electrical activities ro
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Introduction
Please refer to Volume II for the electrical activities.
337
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Chapter 5 Safety method
statement
339
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Introduction
ICS
Name of Business Unit:
SITE COMMISSIONING
Title/Description of activity
Date/period of work (see note 1): TBA by Installation and Commissioning Manager
Place/location of work (see note 1): TBA
Number of/details of people involved in work. TBA by Installation and Commissioning Manager
Site-specific hazards (see note 2) ‘’‘’
Environmental considerations (see note 3) ‘’‘’
Welfare arrangements (e.g. toilet, changing,

mess and washing facilities) (see note 4) ‘’‘’
Significant hazards associated with activity Refer to accompanying Risk Assessment(s)

(e.g. noise, lifting, chemicals, etc.):
Possible risks to non-Rolls-Royce personnel: Refer to accompanying Risk Assessment(s)

(see note 5)
341
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1) All electrical work is to be undertaken under the control

of an Electrical Permit to work.
2) Personnel to physically ensure that the equipment is
electrically isolated before starting to work on it.
3) Check for the presence of gas before opening any junc-
tion box or exposing terminals.
4) Check that all electrically operated commissioning
equipment is certified suitable for the area in which it is
to be used.
5) Ensure that factory supplied equipment e.g. temporary
flushing rig, is checked prior to use, particularly the
electrical items; check that these have current electrical
safety tags and that all cables are in good condition.
6) Inspect all hand tools to check that they are in good
condition at the start of every shift, especially the cable.
7) All hand-tools operating at 110 VAC to be protected by
an ELCB.
8) When working on the engine ignition system, always
observe the warning on the device and in the instruc-
tion manual about the lethal nature of the high-tension
side of the installation.
9) When working with synthetic oil systems the appropri-
ate PPE must be issued and used:- long sleeve
overalls, gloves, goggles/visor, safety shoes, and hard
Precautions to be taken (include control measures hat.
identified in risk assessment(s)): 10)Transportation must be available for quick transfer to
hospital in the event of high pressure injection of syn-
(see note 6) thetic oil.
11) Only personnel aware of the potential hazards must
perform motor rotation checks.
12)Pneumatic testing with nitrogen must be undertaken
strictly in accordance with the design code: ASME
B31.1. Systems involved are the fuel gas system and
the WACAC system. At all times during the test the
area must be barricaded off to exclude all non author-
ised personnel, and advising the danger from stored
energy.
13)Nitrogen cylinders must come from a recognised sup-
plier, be certified and undamaged. All tools, gauges
and connections must be appropriate for the job. If cyl-
inders have been stored in cold conditions they must
be allowed to equalise with the system to be tested be-
fore use.
14)Ensure that all personnel involved with flushing are
aware that the oil will be heated up to 700C, therefore
only long sleeve overalls should be used.
15)Appropriate masks should be used when venting or
bleeding circuits containing synthetic oil heated to high
temperatures to prevent the possible inhalation of
fumes.
16)Only trained approved personnel must be engaged in
working in restricted spaces.

EXPORT CONTROLLED
17)Competent certified personnel must only install tempo-

rary access equipment. Ladders must be in good
condition and securely tied off at the correct angle.
18)Only trained approved personnel must be engaged in
working at height.
19)All personnel involved in the commissioning of the fire
extinguishing system must be aware of the potential
hazards involved and be aware of the nearest emer-
gency exit.
Precautions to be taken (include control measures 20)The appropriate MSDS (Material Safety Data Sheet)
identified in risk assessment(s)): must be readily available for fluids being used in the
commissioning, and all personnel must be aware of the
(see note 6) hazards.
21)Ear defenders must be issued and used when engine
cranking or the running of the hydraulic start package
is imminent, and at all times when the engine is
running.
22)All commissioning must be performed in accordance
with agreed test procedure under the direction of the
Rolls-Royce senior test engineer who will maintain a
log of involved personnel and take a roll call in the
event of an emergency evacuation.
1) Special factory supplied flushing kit.
2) Electronic/electrical commissioning equipment.
3) Two way radios.
4) Nitrogen skid with valves and pressure gauge.
Equipment to be used (including PPE): 5) Access equipment.
6) PPE- safety shoes, hard hat, long sleeved overalls,
gloves, visor/goggles, masks, ear defenders.
7) High visibility barriers to ensure that only authorised
personnel enter the test area.
1) Site induction.
Communication requirements: 2) Appropriate technical literature.
3) Possible permit to work.
Contact and emergency contact names/numbers/ Site Manager/Site Safety Officer
arrangements: Tel: TBA Installation and Commissioning Manager.
Emergency Procedures: Site induction to identify
Site or area access requirements/arrangements Site induction to identify
Electricity
An electrical permit to work, and the site / station regulations must cover all electrical work.
Electricity - above 240v

Generally, voltages above 240V, are confined to larger electric motors, and commissioning activities involving
these should be restricted to checking rotations. It may be necessary to change phases if the rotation is found
343
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to be incorrect. The person involved should personally ensure that the equipment they are working on has been
isolated at the motor control centre by actually locking the breaker in the OFF position or the physical removal
of the fuse/fuses or some other positive means of isolating the circuit being worked on. Irrespective of the status
of the equipment, a check for the presence of gas must be performed before any junction box is opened or ter-
minals exposed.
Electricity - up to 240V
This covers all other electrical devices (except the ignition system) including small motors, detection equipment,
controls, immersion heaters, low voltage devices, special commissioning equipment (including hand held me-
ters and signal generators), electric hand tools, two-way radios and other communicating devices.
All commissioning equipment must be certified, and in the case of hand tools and temporarily installed equip-
ment, these must be checked at the start of each shift for damage, particularly the supply cables. These items
must also be protected by ELCBs (Earth Leakage Circuit Breaker), and be suitable for use in hazardous areas
were appropriate.
Irrespective of the status of the unit, a check for the presence of gas must be performed before any piece of
equipment is used that is not certified for use in a hazardous area.
Note
Battery operated meters and signal generators, two-way radios and other communicating
devices must be certified if they are to be used in designated hazardous areas.
Electricity - ignition system
! Warning
The electrical discharge from the high-energy ignition system is LETHAL. The low-tension side
of the unit must remain isolated until immediately prior to a fired run.
Before the igniters are removed, a period of at least two (2) minutes must be allowed to elapse after the isolation
of the low-tension supply, to allow the current to decay.
Synthetic oil
Synthetic oil is used in the industrial engine lubricating and hydraulic systems. This oil can be considered as
“non hazardous” if the “controls” detailed on the appropriate MSDS are applied. However, during commissioning
it is possible that adverse conditions may occur during which contact with this oil may be unavoidable. It is there-
fore essential that all personnel involved are made fully aware of the steps that need to be taken should contact
with synthetic oil occur.
During the initial commissioning of the lube oil and hydraulic oil systems it is advisable that the PPE detailed in
the appropriate MSDS be used even when contact with the oil is not anticipated. The oil in these systems will
be at high pressure (up to 76 bar) and leaks may cause the oil to be injected under the skin; this situation will
require immediate hospital attention and this possibility must be borne in mind during commissioning.

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! Caution
During pre-commissioning (flushing) the oil may be heated up to 70C (158F) and the
possibility of burns from contact with hot surfaces will be present. Appropriate PPE must be
used i.e., long sleeve overalls and gloves.
When the oil is heated to high temperatures during flushing the possibility of coming into contact with fumes is
increased. Extra care must be exercised when venting or bleeding circuits and appropriate masks must be used
to prevent the inhalation of fumes.
Checks required to satisfy the flushing procedure involve the taking of oil samples; when these are being taken
/ analysed care must be taken to avoid contact with the oil or the inhalation of fumes.
After the satisfactory completion of flushing, it will be necessary to remove the various pieces of temporary flush-
ing kit; care must be exercised to prevent the contamination of the systems during this procedure or serious
damage to the engine may result. Do not use “red caps” or other tapered blanks as these may be left in the
circuit by mistake.
Note
Clothing that is contaminated with synthetic oil should be laundered separately before re-use.
Leather articles cannot be decontaminated and should be destroyed to prevent reuse.
Motor rotation checks

To complete motor rotation checks it will be necessary to remove the guards that protect the coupling.
! Caution
Care must be taken to keep well clear of the rotating elements during this operation as
entanglement is possible which would lead to injury.
Replace the guards as soon as the correct rotation has been established.
Pressure testing with nitrogen

As the pipework systems for the turbine and the gas generator are designed to ASME B31.1 they should be
tested according to the requirements of this code. The WACAC (Water Air Cooled Air Cooler) system and the
fuel gas system must be checked for leaks using compressed nitrogen.
When the initial pressurisation of the system under test is in progress, the area must be restricted using a phys-
ical barrier with highly visible signs warning of the danger from stored energy, and the area kept clear of all
personnel. Once the pressure has been reduced to the level required in the code, the person conducting the
actual leak test is allowed to enter the test area but must be issued with, and use, the appropriate PPE:
• Hard hat
• Safety shoes
• Overalls
• Gloves
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• Visor / Goggles
Use the blanks / spades called up on the B.O.M. to test the WACAC and the fuel gas system. Perform each test
procedure in one (1) operation so as to reduce the possibility of contaminating the systems or the engine.
! Caution
As part of the HVAC system is installed on the roof of the enclosure, working at height will be
involved; it is essential, therefore, that all personnel involved in this procedure are trained and
authorised to work at height. It is also important that any temporary access equipment is
installed by competent authorised personnel and that ladders are installed at the correct angle
and adequately tied off.
Nitrogen for this test must be supplied by a recognised distributor and care must be taken to ensure that the
cylinders in which it is supplied are certified and undamaged. All connections and tools used to operate the
valves must be correct for the job. A pressure gauge with a calibration certificate must be used to ensure that
the system is not over-pressurised. If the cylinders have been stored in cold conditions, then they should be
allowed to equalise with the temperature of the system to be tested before use.
Working with restricted access / obstructions

During commissioning it will be necessary to make adjustments or temporary modifications to equipment with
restricted access / obstructions, (e.g. under the engine). It will therefore be necessary for personnel to be made
aware of the potential hazards associated with these activities. Necessary PPE should be issued and used:
• Overalls
• Hard hats
• Safety shoes
• If synthetic oil is in use, safety goggles.
Fire and gas system

During the majority of the commissioning this system will be passive, however for the portion of the commission-
ing involving actual fired operation the system will be either active or be capable of manual operation.
! Caution
All personnel must be aware of the potential hazards associated with the discharge of the CO2
system and be prepared to evacuate the protected areas should the system activate. Escape
routs must be adequately signed and all personnel aware of the nearest exit. Only essential,
trained, authorised personnel are to be involved in this operation.
Preparation for engine crank

Prior to the first crank of the engine it will be necessary to carry out a complete check of the engine and its as-
sociated systems to ensure that all the temporary flushing equipment etc. has been removed, that all the
controls and valves are in the correct position, that any necessary system links have been installed / removed.

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Initial crank of the engine

Before this section of the commissioning commences the unit and the immediate area around the unit is to roped
off using a highly visible system complete with warning signs. Ensure that no work is inadvertently being carried
out by others on the roof of the unit enclosure or its associated modules. Only the Rolls-Royce commissioning
team should be allowed inside the barriers.
! Warning
To prevent any possibility of electrocution from the ignition circuit, isolate the system by
removing the fuses.
It is a requirement that no personnel shall be inside the engine enclosure while the starter motor is running; con-
trol of this requirement is the responsibility of the senior commissioning engineer.
During the rundown of the various engine starts there is a requirement to listen to the engine for unusual noises
and to check for leaks. Care must be exercised during the checks for leaks as they may be high pressure syn-
thetic oil, therefore the appropriate PPE must be used and the facility to transport personnel to the local A & E
Hospital in an emergency, must be available.
When checking the strainers and MCDs contact with the synthetic oil is probable, ensure that the appropriate
PPE and controls detailed on the appropriate MSDS are used:
• Long Sleeved Overalls
• Safety Shoes
• Goggles
• Gloves.
Note
Clothing that is contaminated with synthetic oil should be laundered separately before re-use.
Leather articles cannot be decontaminated and should be destroyed to prevent reuse.
Washing the engine

Immediately prior to the operation of the engine, and possibly during the commissioning, it will be necessary to
operate the water wash system. This system has to be filled with the approved fluids; the controls and PPE de-
tailed on the appropriate MSDS for these fluids must be followed.
Noise
When the engine is running, appropriate PPE in the form of ear defenders must be issued and used at all times.
The hydraulic start package generates sufficient noise to require the use of ear protection when working nearby.
Hazardous atmospheres
During this series of tests there is the potential for the existence of a hazardous atmosphere, due to the pres-
ence of natural gas, to form inside the engine enclosure, the air intake system or the exhaust system. It is
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essential that the purge sequence for the engine is correctly set and applied at every start. It is also essential
that the enclosure ventilation system is operating to remove any hazard prior to the start of the unit. The fire
protection system must also be operating to give warning of hazardous atmospheres across the whole installa-
tion. The CO2 extinguishing system must be active or at least capable of manual operation.
Under normal circumstances the above actions will be automatic, but it must be appreciated that this is a com-
missioning situation and things will, on occasions, not perform as expected. The test team must remain vigilant
at all times, especially when entering the engine enclosure, the air intake system or, in exceptional circumstanc-
es, the exhaust system, for the presence of gas or CO2.
For more information regarding "Hazardous Atmospheres", please refer to GER 0087 found under “Engineering
standards” on page 373.
Test schedule
This is to be carried out strictly in accordance with the agreed test schedule.
For this, and subsequent testing, the equipment will be at its most hazardous; the fuel gas, high tension elec-
tricity, high pressure synthetic oil, high pressure hydraulic starter systems and the fire protection system will all
be in operation. It is therefore essential that only the authorised test team are present inside the cordoned off
area at this time.
The Senior Rolls-Royce Test Engineer must maintain a log of the personnel involved in the test and in the event
of an emergency evacuation, must hold a roll call in the designated muster point to ensure that all personnel
have evacuated the site. The muster point and the signals used to initiate an evacuation must be conveyed to
all the personnel involved during a pre test “tool-box” talk.
Prepared by: Signed:
Notes
1) For generic method statements, date and place of work are to be completed on a job-specific basis. Meth-
od statement to be signed-off for each job.
2) Hazards associated with the site itself or other site activities must be identified by the site owner/manager
and addressed by this method statement and accompanying risk assessments. Complete table below to
indicate hazards present. If appropriate, Rolls-Royce personnel should be accompanied by site personnel
to ensure that site hazards are identified and understood.
3) Environmental considerations should address both general and site-specific issues, such as noise, ioniz-
ing radiation, water-borne and air-borne pollution, disposal of waste materials.
4) The use of site facilities must be agreed with the site owner/manager.
5) Consider risks to site personnel, public, plant and premises.
6) This method statement must be accompanied by risk assessments relevant to the activities covered and
must address any site-based hazards identified by the site owner/manager. Generic risk assessments
may be acceptable provided all site-based hazards are assessed.

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Note
The overall method statement for a particular working activity may be composed of more than
one generic method statement.
Table 1 - Hazard Checklist
Indicate if any of the following apply to the work activity (check relevant boxes)
(ensure that site-specific hazards are included)
Plant and Equipment Place of Work
 Crushing  Buried services
 Impact  Emergency escape route
 Puncture  Falling objects

 Trapping  Housekeeping/tidiness
 Contact (cutting, friction, abrasion)  Obstruction
 Display Screen Equipment  Overhead cables
 Electrical (shock/burn/explosion)  Safe means of access
 Entanglement  Slips and trips
 Ejection (work piece/tool, etc.)  Structural integrity

 Hand tools  Trespassers
 Noise/Vibration  Work near liquids
 Pressure (release of energy)  Working at height (e.g. roof, ladder, scaffold)
 Radiation (ionising, non-ionising) Materials and Substances
 Stability/overload  Asphyxiants
 Stored Energy (spring, hoist, suspended load)  Combustible materials
 Thermal  Corrosives/irritants
 Vehicles and traffic movement  Dust fires & explosions
Work Organisation  Flammable/explosive substances
 Lone working  Gases, fumes & vapours
 Stress  Health hazards by ingestion
 Working hours  Oxidising substances
 Work in public areas  Particles & mists
Methods of Work Working Environment
 Ergonomics  Confined space
 Manual Handling  Fire
 Posture  Lighting
 Repetitive movements  Noise

Other  Temperature
 Environmental aspects (e.g. waste disposal)  Ventilation
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 Natural hazards (e.g. weather)  Natural hazards (e.g. weather)

Chapter 6 Risk assessment
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352 L:\ICS\WIP\Methods\ICS Manuals\M.A606 KENKO BOLIVIA\Vol 1\risk_assessment_1.fm 14 May 2012

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Assessment with existing control

measures
Business: Rolls-Royce
Department: ICS
Dept. no.:
Location: Trent Phase IV DRAFT ICS Manual
Activity (or area) being assessed: SITE COMMISSIONING
People affected
Rolls-Royce: Frequency/duration:
Others: Frequency/duration:
Assessment ref. no. SO#
Date of assessment:
Assessor(s)/team:
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Description Signature
Accountable Manager
Lead Assessor
Signed
Name (print)
Position
Date
Periodic reviews – maximum

intervals for activities with:
Medium risk (but ALARP) - annually
Low risk - three-yearly
1st Review
Date:
Name:
Signed:
2nd Review
Date:
Name:
Signed:
3rd Review
Date:
Name:
Signed:
4th Review
Date:
Name:
Signed:

Risk assessment ro
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F)
E) Consequence (outcome)
Foreseeable
C) D) Hazardous cause
Hazard event (cause of Valu G) H) J)
(potential (what hazardous e Existing control Probability Risk
for harm) happens) event) Details of harm 1 to 5 measures used 1 to 5 1 to 25
Ladder in good
Example:
Fall from lad- condition, at cor- 9
Working at Loss of balance Broken limbs 3 3
der rect angle and Med.
height
tied off
Obtain permit to
1) Electric- Electric shock work.
ity: above / burns Isolate equip-
Equipment not
240v. – received as a Electrocution, ment at the MCC 8
isolated before 4 2
Three phase result of work- burns. by locking off the Med.
work begins.
electric ing on live breaker, or
motors. equipment. removing the
fuses.
Obtain permit to
work. Isolate
2) Electric-
equipment at the
ity: up to Electric shock
MCC or the
240v:- single received as a Equipment not
Electrocution, appropriate con- 8
phase result of work- isolated before 4 2
burns. trol board by Med.
motors, & ing on live work begins.
locking off the
immersion equipment.
breaker, or
heaters.
removing the
fuses.
Use only
inspected / certi-
fied equipment.
Were possible
this should oper-
3) Electric-
ate at 110v and
ity:-Tempo-
Electric shock Damage to sup- be protected by
rary
due to wiring ply cables by Electrocution, ELCBs. Hand 8
Flushing 4 2
fault or short site traffic; wear burns. tools should be Med.
equipment &
circuit. and tear. battery operated
hand held
were possible.
tools.
Inspect supply
leads and hand
held tools at the
start of every
shift.
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F)
Foreseeable
Removing ignit- Physically
ers with the sys- remove the fuses
tem still active from the control
Electric shock
4) Electric- or not having circuit. Ensure
from high ten- 8
ity:- Ignition allowed the rec- Electrocution. 4 that the time rec- 2
sion side of Med.
System. ommended ommended in the
system.
amount of time manual for the
to elapse after current to decay
isolation. is observed.
5) Electric-
ity:- al elec-
trical
devices,
including
hand held
meters, sig-
nal genera- Use of un-certi- Only use equip-
tors, fied equipment Multiple fatalities. ment that is
10
detectors, Explosion. inside a desig- Extensive dam- 5 intrinsically safe 2
Med.
two-way nated hazard- age. or explosion
radios and ous area. proof.
other com-
municating
devices, and
temporary
commission-
ing equip-
ment.

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F)
Foreseeable
1) If injection
occurs the wound,
irrespective of the
appearance, must
1) Leak in high 3 2 6
be evaluated
pressure sys- Med.
1) Oil is immediately by a
6) Synthetic tems.
injected under physician as a
Oil: Use appropriate
the skin or medical emer-
2) Spills during PPE and controls
any other part gency. Early surgi-
Note. changing/ detailed on the
of the body. cal treatment
Some syn- cleaning strain- COSHH (Control
within the first few
thetic oils ers or MCDs Of Substances
2) Oil in con- hours may signifi-
are more Hazardous To
tact with the cantly reduce the
hazardous 3) Splashes Health) and
skin. ultimate extent of
than others; during chang- Safety Data
the injury.
this analy- ing / cleaning Sheets for the oil
3) Oil in con-
sis takes the strainers or used.
tact with the 2) May cause irri-
worst case. MCDs or during 1 3 Low
eyes. tation of the skin.
checking for
leaks. 2 3
3) May cause irri-
tation to the eyes;
may require hospi-
tal attention.
Burns to the
7) Synthetic skin due to Accidental con-
Use appropriate
Oil: heated accidental tact with the hot May cause burns /
PPE. i.e.:- long
contact with surfaces during blisters to unpro- 6
up to 70o C. the tank or checks/ adjust- tected areas of
2 sleeved overalls, 3
Med.
during flush- safety shoes,
other parts of ments to the skin.
ing. gloves.
the oil sys- systems.
tems.
Use appropriate
PPE as detailed
Increased risk Accidental on the COSHH
8) Synthetic of exposure to exposure to and Safety Data
May cause irrita-
Oil: fumes from fumes when Sheet for the oil
tion to the eyes.
Heated up the synthetic venting / bleed- used. Use an Air
May cause irrita- 6
oil during ing oil circuits. 2 Supplied Respi- 3
to 70oC. flushing due Also inspecting
tion to the nose,
rator if work
Med.
During flush- throat and respira-
to the ele- / changing inside an
ing. tory tract if inhaled.
vated temper- MCDs and enclosed area is
ature. strainers. unavoidable in
the presence of
oil fumes.
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Risk assessment ro
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F)
Foreseeable
Standing too
close to the
Use appropriate
rotating ele-
When check- PPE i.e.:- over-
ments while
ing motor Items may alls, fastened to
wearing inap-
rotations it is become entan- the neck. Do not
9) Entangle- propriate cloth- 6
necessary to gled in the rotat- 2 have loose items 3
ment. ing (loose), Med.
remove the ing element exposed that
neck ties,
protective causing injury. may be drawn
exposed identi-
guards. into the rotating
fication tags
parts.
around neck,
etc.

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F)
Foreseeable
1) Ensure that
Test certificates
are available for
each component
in the system.
2) Check that the

gaskets are of
the correct rat-
ing.
3) Check that all

joints are torqued
up to the correct
1) Individual
value.
components /
pipe spools not
4) Ensure that
pressure tested
Failure of the regulator and
10) during manu-
component or gauge on the
Release of facture.
joint during nitrogen supply
Energy:
pressure test- bottles are certi-
Pneumatic 2) Failure of Damage to assets.
ing of: fied and oper-
testing. joint. 9
- WACAC and 3 ated by a 3
Injury to person- Med.
its associated competent per-
(Refer to 3) Joints not nel.
pipework son.
ASME tightened to the
B31.1 – correct torque.
- Fuel gas Ensure that all
1998)
system personnel are
4) Accidental
kept well clear
over pressurisa-
during the ini-
tion of system
tial pressurising
during test.
of the system.
Once the pres-
sure has been
reduced to the
requirement of
the code, the
person carry-
ing out the leak
test must wear
appropriate
PPE: Hard hat.
Safety shoes,
Overalls, Gog-
gles & Gloves.
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F)
Foreseeable
1) Ensure that all
permanent &
temporary
access equip-
ment is in good
1) Slip on deck- order and cor-
Fall on perma- ing. rectly installed.
nent / tempo-
2 3 6
rary access 2) Loss of bal- Abrasions sprains, 2) Avoid working
11) Working Med.
equipment. ance. bruises. at height if deck-
at Height. 9
Broken limbs. ing is wet due to
3 3 Med.
Fall from lad- 3) Working in rain. Ensure that
der. poor weather ladders are in
conditions. good order,
3) Avoid working
at height in poor
weather condi-
tions.

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F)
Foreseeable
1) Clean up oil
spills immedi-
ately; use protec-
tive footwear with
anti-slip soles.
Use goggles if oil
systems are
pressurised.
2) Use protec-
tive headgear
(Hard Hat).
3) Wear long
sleeve overalls
1) Slip on oil. Making adjust-
and gloves.
ments under the
2) Low head- engine and / or Sprains, Bumps,
room. on the auxiliary Abrasions, Cuts, 2 3 6
12) 4) Evacuate in a
skids. Burns. Med.
Restricted safe orderly fash-
3) Burns from
access ion, using a pre-
hot oil pipe-
Obstruc- determined
work. Accidental dis-
tions. escape route to a
charge of C02 Possible asphyxia- 4 2 8
designated mus-
4) Emer- system, or the tion. Med.
ter point.
gency evacu- detection of
ation. gas.
When working
in an area with
restricted
access or
obstructions, it
is advisable
that two people
work together
to provide
assistance if
one gets
trapped in the
case of an
emergency
evacuation.
13) Stored No personnel
Major damage to
Energy. Failure of inter- allowed inside 12
Starter motor engine. 4 3
Starter nal compo- the enclosure High
disintegration. Major injury to per- 3 1
Motor run- nents. when starter is 3 Low.
sonnel.
ning. running.
361
Risk assessment ro
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F)
Foreseeable
- Ensure that the
hydraulic oil sys-
tem has been
leak tested previ-
ously.
Checking for
leaks during ini- - Wear long
14) Injection of oil
Failure of joint tial Crank of the sleeved overalls,
Pressure. under skin. 6
on hydraulic engine. 3 gloves and gog- 2
Release of Med.
oil system. - Synthetic oil gles.
energy. Eye contact.
pressurised up
to 76 bar. - Have emer-
gency facilities
available to con-
vey injured per-
sonnel to
hospital.
The proprietary liq-
Use appropriate
Splashes / uids added to the
PPE:
Hose failure water to wash the
Water wash - Long sleeve
15) Health when filling / engine, and the
additives overalls, gloves
Hazards. using the Water inhibiting fluids,
coming in and goggles. 6
Wash system: can cause irritation 2 3
contact with: Med.
Irritating - Prior to run- if they come in
- Eyes Refer to appro-
materials. ning the engine. contact with the
- Skin priate COSHH
- At the end of eyes and skin and
sheet for the flu-
commissioning. may require hospi-
ids used.
tal attention.

Risk assessment ro
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F)
Foreseeable
1) Always use
ear defenders
when working
near to the
hydraulic starter
pack when it is
running or when
there is a possi-
bility of it starting
Damage to
up.
hearing as a
result of:
2) Never enter
the engine enclo-
1) Standing
sure or open the
too close to
The engine and enclosure door
the hydraulic
the hydraulic Hearing loss when the engine 9
16) Noise starter pack- 3 3
start package in Tinnitus etc. is operating Med.
age.
operation. above IDLE
speed. Always
2) Entering or
use ear defend-
opening the
ers when enter-
door to the
ing the enclosure
engine enclo-
when the engine
sure.
is running at Idle
speed or running
down. Ensure
that the enclo-
sure doors are
fitted with signs
warning of the
potential hazard
from noise.
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F)
Foreseeable
1) Ensure that
the gas detec-
tion system is
operating and
that the gas
detectors in the
filter-house are
correctly posi-
tioned and cali-
brated.
2) Ensure that
the gas detectors
in the air intake
system are cor-
rectly positioned
and calibrated.
3) Ensure that
1) Gas is drawn the fuel gas line
into the engine has been leak
through the fil- tested in accord-
tration system. ance with ASME
17) B31.1. Ensure
Hazard- 2) Gas is drawn that the gas
Explosion due Multiple fatalities.
ous into the engine detectors inside 10
to auto-igni- Extensive dam- 5 2
Atmos- enclosure the engine enclo- Med
tion. age to Assets
pheres. through the sure are cali-
Natural Gas. ventilation sys- brated.
tem. Check that the
purge cycle for
3) Leak in fuel the air intake and
gas system. exhaust train on
engine start-up
has been calcu-
lated to ensure
that the starter
motor rotates the
engine for the
necessary time to
complete the
required changes
of air. Also check
that the enclo-
sure vent fans run
for the necessary
time to complete
the required
changes of air
before an engine
permissive signal
is given.

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F)
Foreseeable
1. Ensure that
the system has
been fully com-
missioned by
Siemens (for-
merly Preussag)
before engine
commissioning
starts and that
the necessary
certificates are in
place.
2. Ensure that
the fuel gas sys-
tem has been
tested and that
the necessary
certificates are in
Activation
place.
caused by:
18. Discharge of 1. Malfunction
Hazard- CO2 system 3. Some "fire
of system.
ous spotters" detect
with person- Possible asphyxia-
4 and react to ultra 2 8 Med
Atmos- nel inside the 2. Detection of tion.
pheres. violet light.
protected Gas.
CO2 Ensure that the
area.
detection sys-
3. Detection of
tem is de-acti-
Fire.
vated before
unusual forms of
illumination are
used. e.g. Televi-
sion / Video
lights.
All personnel
working in an
area protected by
a CO2 system
must be aware of
the potential haz-
ard associated
with the activation
of the system,
and have a clear
route of escape to
a pre designated
muster point
available to them.
365
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Assessment of risk reduction actions
P) I confirm that the

proposed actions have
been completed and that
K) the expected risk
Proposed l) Expected risk after completion M) reduction has been
actions of actions Planned achieved.
(risk action N) Actual
reduction completio completion
measures) Consequence Probability Risk n date date Name Signature Date
Re-assess
risks to show
how proposed
actions will be
effective in
reducing the
risk.
Also consider
whether any
new hazards
will be intro-
duced
Consequence Probability
Incredible
Extremely Improbable Occasional Probable Frequent
unlikely Unlikely but Likely to Likely to Regular or
to ever may occur occur occur continuous
occur exceptionally sometime often occurrence
People Assets Environment Reputation 1 2 3 4 5

Exten- Interna-
Multiple Significant
sive tional 5
fatalities harm*
damage impact
High
Moderate,
Single Major National
long term 4
fatality damage impact
harm*
Local- Moderate, Consider-
Major
ised short term able 3 Medium
injury
damage harm* impact
Lost
Minor Low impact, Limited
time 2
damage little harm* impact
injury Low
First aid No dam-
No impact* No impact 1
injury age

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R Lead Assessor Accountable Manager
Signed
Name (print)
Position
Date
Note
* Refer to “Environmental Aspects and Impacts Assessment methodology and EnvAID user’s guide” for
explanation of environmental probability and consequence categories.
Guidance on completion of risk assessment form
Box/Column Explanation (for detailed guidance refer to risk assessment guidance document)
Provide details of the activity being assessed and the business and department to which it relates.
Where the risk assessment is generic it should be clearly stated.
A
Indicate the people who could be affected (including contractors and the public) and the frequency
and duration of exposure – precise details are not required.
A unique reference number should be allocated to the assessment, and the date of the initial assess-
B
ment and the main parties involved should be recorded.
Hazard: The hazard is the thing with the potential for harm, such as a flammable substance, rotating
machine or deep water. Record all of the significant hazards associated with the activity being
assessed. Ignore any trivial hazard.
The form provides space for listing six hazardous events (i.e. outcomes) - if more are needed, con-
C
tinue on an additional sheet.
Although the risk assessment matrix covers risks to people, assets, environment and reputation, each
of these risk areas should be considered separately, e.g. consider environmental hazards indepen-
dently.
Hazardous Event: Give a very brief description of the hazard scenario or event - i.e. what happens
D
that could lead to harm.
Foreseeable cause: Record the plausible causes of each hazard being released or the foreseeable
causes of exposure to the hazards.
E
E.g. how the substance is released, how a person becomes trapped in a dangerous machine, how a
person comes into contact with deep water.
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Consequence: This column is divided into two parts. The first gives brief details of the outcome of the
hazardous event, whilst the second part records the value associated with the harm, taken from the
risk matrix. Clearly the description of the harm should relate to the appropriate category in the matrix.
First aid injury: local first aid treatment received but no significant lost time.
Lost time injury: off-site medical treatment or short-term lost time (e.g. days).
F Major injury: immediate major trauma long-term lost time (e.g. weeks)
It is important to be realistic is considering consequence, and although unlikely events should be con-
sidered, they should nevertheless be plausible. Note that if there is more than one plausible outcome
from a hazardous event, each will need to be considered separately.
Taken together, columns C to F should provide an understanding of the hazardous event being con-
sidered.
Existing Control Measures: The presence of any existing control measures may reduce both the
probability of an incident occurring and the scale of the consequences, and should be recorded to
ensure that they are taken into account by the risk assessment and not overlooked.
This record of control measures will also be useful when preparing a written safe system of work,
G which should draw from the risk assessment.
Any control measures specified should be those that are actually used, and should be adequate for
the purpose and regularly reviewed to ensure that they continue to be maintained as effective con-
trols. If there is doubt about the genuine usage or effectiveness of a control measure it should not be
included as a risk reduction measure.
Probability: Using judgement based on experience and historical evidence, estimate the probability of
each hazardous event occurring using the categories given in the risk matrix. In considering the prob-
ability account should be taken of the control measures that are in place providing that they are genu-
inely used and of benefit.
If in doubt about which category to select, err on the side of caution. Further guidance on the selection
of probability categories relates to the assessment teams’ experience, as follows:
H Incredible: No one in the team/workgroup has heard of this occurring in the industry.
Improbable: One person in the team/workgroup knows of someone who has experienced this.
Occasional: One person in the team/workgroup has experienced this at least once in the last two
years.
Probable: All persons in the team/workgroup experience this at least once a year.
Frequent: All persons in the team/workgroup experience this more often than not when doing this
activity.
Risk: The value of risk is determined by combining (multiplying) the values sexed for consequence
J and probability for a given hazardous event. The risk matrix facilitates this and results in one of three
risk categories being selected, i.e. High, Medium or Low.

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Proposed Actions: The tolerability of the risk assessed in column H will determine whether further
actions are required for risk reduction.
High risks cannot be tolerated under any circumstances and will require immediate action to reduce
the level of risk to ‘as low as reasonably practicable’. If necessary this may require temporary suspen-
sion of an activity or the installation of temporary control measures.
Medium risks - judgement will need to be made on the urgency of further action to reduce the risk to a
K level that is ‘as low as reasonably practicable’. In specifying actions for further control measures, con-
sider both immediate (interim) actions and long-term (permanent) solutions.
Low risks are broadly tolerable but should be kept under review and reduced further wherever rea-
sonably practicable. However the principle of continuous improvement should be employed to con-
tinue to drive down risk where economically valid.
In deciding what action to take to reduce risks a hierarchical approach should be taken, further details
of which are given in Section 2.3.3 of the main document.
Expected risk after completion of actions: Once actions have been selected the risks should be
reassessed to ensure that the required risk reduction will be achieved, i.e. that the revised level of risk
L is tolerable. If it is not, alternative or additional actions will be required.
Note that actions intended to reduce risks may also introduce further hazards and therefore risks – it
is therefore important to consider any additional hazards in the reassessment.
Planned action completion date: When a satisfactory means of risk reduction has been determined
through appropriate actions, it is important that they are actually carried out to an acceptable time-
M
scale. The planned completion date will need to be carefully considered, and if the activity is allowed
to proceed in the meantime, additional precautions may need to be put in place temporarily.
Actual completion date and confirmation of completion: When a risk reduction action has been
completed, the date should be recorded and the action signed-off. This is an important part of the pro-
cess as any actions not enforced will render the risk assessment useless. The sign-off will also pro-
N/P vide an auditable record.
If the initial risk assessment for a given hazard has concluded that no additional actions are neces-
sary, columns L, M, N and P will not need to be completed. Temporary control measures need to be in
place before the activity begins.
Periodic reviews: The completed risk assessment should be reviewed periodically to ensure that it
remains up-to-date and relevant to the activity.
Maximum intervals for review relates to the level of residual risk associated with the activity, and are
as follows:
Medium Risk (which have been justified as ALARP) – annually
Q
Low Risk - every 3 years.
Clearly high risks are not tolerable and so activities will not have a high residual risk.
In addition to periodic reviews, risk assessments should be revisited:
whenever significant changes in circumstances occur (including changes to the operation of the activ-
ity or in light of new legislation and other requirements); following any incident.
Sign-off: On completion of the risk assessment the form should be signed-off by the assessor and by
R the manager who is accountable for the working activity or area which has been assessed. Sign-off
may be before box P is signed to verify that actions have been completed.
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Plant and Equipment Place of Work
 Crushing  Buried services
 Impact  Emergency escape route
 Puncture  Falling objects

 Trapping  Housekeeping/tidiness
 Contact (cutting, friction, abrasion)  Obstruction
 Display Screen Equipment  Overhead cables
 Electrical (shock/burn/explosion)  Safe means of access
 Entanglement  Slips and trips
 Ejection (work piece/tool, etc.)  Structural integrity

 Hand tools  Trespassers
 Noise/Vibration  Work near liquids
 Pressure (release of energy)  Working at height (e.g. roof, ladder, scaffold)
 Radiation (ionising, non-ionising) Materials and Substances
 Stability/overload  Asphyxiants
 Stored Energy (spring, hoist, suspended load)  Combustible materials
 Thermal  Corrosives/irritants
 Vehicles and traffic movement  Dust fires & explosions
Work Organisation  Flammable/explosive substances
 Lone working  Gases, fumes & vapours
 Stress  Health hazards by ingestion
 Working hours  Oxidising substances
 Work in public areas  Particles & mists

Methods of Work Working Environment
 Ergonomics  Confined space
 Manual Handling  Fire
 Posture  Lighting
 Repetitive movements  Noise
Other  Temperature
 Environmental aspects (e.g. waste disposal)  Ventilation
 Natural hazards (e.g. weather)  Natural hazards (e.g. weather)

Chapter 7 Engineering
standards
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Introduction
This chapter contains the latest, at the time of publication, Rolls-Royce engineering standards, GEMs, GERs,
and other miscellaneous documents applicable to this project. Ensure that you are working from the current re-
vision for your project prior to completing any work within this manual.
If a referenced document is misplaced or omitted, please contact the PLL (Project Logistics Leader) at RRESI
Mt. Vernon for another copy.
Engineering standards
• GEM 0009 - Regulator and Valve Settings
• GEM 0011 - Safety Risk Analysis in Accordance with the Machinery Directive
• GEM 0018 - Painting Procedure
• GEM 0030 - Hydrostatic Testing for Piping
• GEM 0032 - Tightening of Threaded Fasteners and Torquing Sequence for Flanged Joints and
Rotabolt Applications
• GEM 0033 - Setting and Grouting of Rotating Machinery Including Use of Soleplates and Selection
of Foundation (Anchor) Bolts for Low Temperature Application
• GEM 0034 - Lockwiring Procedure
• GEM 0037 - Pipe Preparation and Cleaning
• GEM 0038 - Flushing Main Lubricating Oil Systems - Factory and Field
• GEM 0039 - Use of Loctite Gasket Forming Compounds
• GEM 0041 - Use of Loctite Locking and Sealing Compounds
• GEM 0042 - Leak Test Procedure
• GEM 0043 - Application of RTV-106 Adhesive Sealant
• GEM 0045 - Skid Levelling Procedure
• GEM 0047 - Procedure for Electrical Testing of a Package prior to Operational Testing
• GEM 0049 - Alignment Procedure - Rim, Face and Dial Indicator Method
• GEM 0050 - Fabrication, Installation, Examination, and Testing of Piping Systems
• GEM 0051 - Trent Phase III Exhaust Assembly Procedure
• GEM 0054 - Install/Radial/Axial/Keyphasor Detector Probes - Rotating Products
• GEM 0055 - Application of Hylomar Aerograde Ultra Jointing Compound
• GEM 0267 - Flushing Trent 60 Electric Starte Gas Turbine Oil Systems
• GEM 0074 - Trent Phase III Exhaust Component Assembly Procedure
• GEM 0076 - Installation and Lubrication of O-Rings
• GEM 0077 - Gas Fuel System Test Procedure For An Industrial Trent Phase III Package - Factory
and Field
• GEM 0084 - Installation of Electrical Conduit and Wiring
• GEM 0085 - RTD Conduit Seal Installation RTD Conduit Seal Installation Techniques
• GEM 0088 - Handling and installing flexible hose
• GEM 0102 - Application of IGS High Temperature Sealant and Gasket
373
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• GEM 0123 - Application of High Temperature Pure Nickel Anti-Sieze Compound

• GEM 0130 - Alignment Procedure - Rotalign® Pro Laser Method
• GEM 0143 - Interior Treatment with Volatile Corrosion Inhibitor (VCI) Crystals for Rust Prevention
• GEM 0144 - Receiving and Storage Instructions for RRESI Rotating Equipment at Customer Site
• GEM 0167 - Industrial Trent Mechanical Handling and Engine Alignment
• GEM 0169 - Industrial Trent Package Gas Turbine Installation
• GEM 0170 - Installed Gas Turbine Package - User Acceptance Test
• GEM 0184 - Pump and Driver Alignment Procedure
• GEM 0263 - Test Procedure - Gas Turbine Package Fire Protection Site Dump Testing
• GER 0018 - Package wiring syatem Engineering and Installation Specification
• GER 0035 - Guideline to Cable and Wire Specifications
• GER 0058 - Trent 60 WLE Water Injection Skid Specification
• GER 0204 - Combined Oil System for the Trent DLE and WLE Gas Turbine Packages
• GER 0070 - Grounding-Earthing Design and Application
• GER 0087 - Hazardous Area Classification
• GER 0118 - Installation and Removal of Trent GT to/from Transportation Stand
• GER 0198 - Signal Separation Requirements for Panels, Packages, and Cross Site Wiring
Gas turbine engineering requirement

• GTER 10201 - Master Applications Installation and Commissioning Schedule
• GTER 10205 - Gas Turbine / Package Interface Checks
• GTER 10209 - Gas Turbine Motoring and Pre Synchronised Running FP
Gas turbine engineering specification

• GTES 10153 - Water Quality Acceptability Criteria for Water Injection for Large Gas Turbine
Energy Applications
• GTES 10155 - Gas fuel acceptability criteria for Industrial Trent DLE
• GTES 10157 - Fuels acceptability criteria for Industrial Trent WLE
• GTES 10245 - Industrial Trent 60 DLE and WLE DF Interface Control Document
• GTES 10504 - Industrial Trent 60 WLE Dual Fuel - Flow Check of Injector Nozzles
Miscellaneous documents
• JTR2424 - P30 Sensor Relocation
• LOP F.2.1 - Pre-Commissioning, Audit Plan
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Chapter 8 Forms
375
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Introduction
This chapter contains the latest, at the time of publication, Rolls-Royce engineering forms. Ensure that you are
working from the current revision for your project prior to completing any work within this manual. If a referenced
document is misplaced or omitted, please contact the PLL (Project Logistics Leader) at RRESI Mt. Vernon for
another copy.
• GEMF 0045 - Skid Levelling
• GEMF 0051 - Trent Exhaust Assembly Record
• GEMF 0064 - Flushing Trent Gas Turbine Lubricating and Hydraulic Oil Systems
• GEMF 0074 - Trent Exhaust Component Assembly Record
377
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Chapter 9 Drawings
379
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Introduction
This section contains the latest, at the time of publication, Rolls-Royce engineering drawings applicable to this
project. Ensure that you are working from the current revision for your project prior to completing any work within
this manual. If a referenced document is misplaced or omitted, please contact the PLL (Project Logistics Leader)
at Rolls-Royce Mt. Vernon for another copy.
Project drawings
Document Rev. Title M.A606
GED00160539 000 AC GENERATOR MONITORING PANEL
GED00168223 000 ASC CONTROL PANEL CIRCUIT DIAGRAM
GED00194250 001 WIRING-ISI
GED00194621 000 ENCLOSURE-GT ACOUSTICS - (STARBOARD SIDE WALL #2)
GED00194626 000 ROOF-ENCL - (ROOF ASSEMBLY #1)
GED00194630 000 ENCLOSURE-GT ACOUSTICS - (DOOR RAIL ASSY.)
GED00194680 001 PIPING-LO SUPPLY-DRAIN
GED00194684 001 LOOP-FLUSHING
GED00194687 000 PIPING-WATER INJECTION
GED00194693 000 PIPING-MIST ELIMINATOR-LOWER
GED00194726 002 WIRING-DISTRIBUTED IO
GED00194728 001 WIRING DISTRIBUTED I/O
GED00194743 001 PIPING-MIST ELIMINATOR-ROOF
GED00195782 001 CONSOLE-L/O
GED00196233 001 TUBING-WATER INJECTION
GED00196974 001 SKID-WATER INJECTION
GED00196975 000 CART-WATER WASH
381
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GED00199937 000 BASE - TURBINE
GED00207460 001 CONSOLE - LUBE OIL
GED00207857 001 Trent 60 WLE COMBUSTION AIR SYSTEM DIAGRAM
GED00207859 001 Trent 60 WLE VENTILATION SYSTEM DIAGRAM
GED00207861 001 TRENT 60 WLE ENGINE IGNITION & INSTRUMENTATION DIAGRAM
GED00207863 001 Trent 60 WLE OIL SYSTEM DIAGRAM
GED00207946 001 Trent 60 WLE P30 PURGE AIR SYSTEM DIAGRAM
GED00207950 001 Trent 60 WLE INSTRUMENT AIR and DEMINIERALIZED WATER DIA-
GRAM
GED00207951 001 Trent 60 WLE GAS FUEL METERING SYSTEM DIAGRAM
GED00207953 002 Trent 60 WLE WATER INJECTION METERING SYSTEM DIAGRAM
GED00207955 001 Trent 60 WLE WATER WASH CLEANING SYSTEM DIAGRAM
GED00207956 000 FIRE AND GAS SYSTEM DIAGRAM
GED00207957 001 Trent 60 WLE ISI SYSTEM DIAGRAM
GED00207959 001 Trent 60 WLE LIQUID FUEL METERING SYSTEM DIAGRAM
GED00208978 001 SKID-LIQUID FUEL FORWARDING
GED00210366 000 UTILITY CONSUMPTION LIST
GED00212174 003 SKID - FUEL FORWARDING
GED00212175 002 SKID - WATER INJECTION
GED00213068 001 DIAGRAM - TRENT 60 WLE IGV/BOV CONTROL
GED00217150 000 PUMP SKID - ISI
GED00219246 001 INLET SPRAY INTERCOOLING
GED00219251 001 LUBE OIL-GAS TURBINE
GED00220838 000 ECS/SIS/PCS UCP OUTLINE
GED00220839 001 ECS/SIS/PCS CONTROL SCHEMATIC
GED00220840 000 ECS/SIS/PCS TOPOLOGY DIAGRAM
GED00220841 002 ECS/SIS/PCS PANEL ASSEMBLY
GED00220842 000 ALARM AND TRIP MATRIX
GED00220843 000 HMI DISPLAY

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GED00220845 000 LOGIC FLOW DIAGRAM
GED00221287 000 GENERAL ARRANGEMENT TRENT 60 WLE
GED00221288 000 FOUNDATION / LOADING TRENT 60 WLE
GED00221289 000 SHIPPING OUTLINE
GED00221290 000 MECHANICAL HANDLING TRENT 60 WLE
GED00221291 000 ELECTRICAL INTERFACE
GED00221292 000 Auxillary Electrical
GED00221293 000 HAZARDOUS AREA CLASSIFICATION TRENT 60 WLE
GED00221295 000 AC Generator P&ID, ToA, and Components List
GED00221298 000 Trent 60 WLE AC Generator Lube Oil System
GED00221307 000 CABLE ROUTING
GED00226332 000 TRENT 64MW GTLO Electric Start Outline
GED00226333 000 TRENT 60MW 60WLE OIL SYSTEM DIAGRAM
GED00226671 000 ASC Control Panel Circuit Diagram
GED00226674 000 AIFH Control Panel Layout
GED00226679 000 AIFH Electrical Installation
GED00227922 000 One Line Diagram
GED00230718 AC GENERATOR GENERAL ARRANGEMENT
GED00232632 AC GENERATOR FOUNDATION LOADING
GED00234372 LINE CUBICAL GENERAL ARRANGEMENT
GED00235373 000 H.V. Single Line Diagram
GED00239644 CAUSE AND EFFECT DIAGRAM
GED00242840 AC GENERATOR OPERATION AND MAINTAINANCE MANUAL
383
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Chapter 10 Spare parts list
This chapter contains the Spare Parts list that the customer purchased
385
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Chapter 11 Questionnaire
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Installation and commissioning manuals

questionnaire
This questionnaire is included in an attempt to ensure that the style of, and the information provided in these
manuals is adequate to facilitate a smooth and timely installation and setting to work of the unit. By completing
and returning this questionnaire, and providing the information requested, you will be assisting Rolls-Royce to
adjust and modify the manuals provided for future projects, thereby allowing us to provide a better and more
efficient service.
1) Were the manuals received on site in time for the commencement of the installation (Yes) or (No)?
2) Were the manuals included on the packing list (Yes) or (No)?
3) Were the manuals received as a full set (Yes) or (No)? If No, please note what was missing.
4) Were the manuals received in good condition (Yes) or (No)?
5) Was the sequence of Activities in Volume 1, found to be generally compatible with the way the installation
was undertaken?
6) Was the information in Volume 1, found to be generally accurate?
7) Are there any additional Activities or additional information that you feel should be added to any of the
above Sections?
Please bear in mind that these Manuals are intended as a "guide" to the Installation & Commissioning
of the unit and not as the "definitive" technical manual. The Operation & Maintenance Manuals
must always take precedence technically.
8) Do you find the format of Volume 2 easy to follow?
9) Bearing in mind that the Revision Numbers on the Drawings and the Rolls-Royce Standards in Volume 2
may be delinquent, do you think that including them in the manuals is helpful?
10)Are there any other constructive remarks or suggestions about the Installation & Commissioning Manuals
that you thing may be helpful.
389
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11)Questionnaire completed by:
Name: Company: Date:

Questionnaire ro
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Questionnaire on spare parts provided for

commissioning
The inclusion of this questionnaire is an attempt to ensure that the spare parts provided have been proven to
be adequate for the Installation and Commissioning of the package. By completing this questionnaire, and pro-
viding the information requested, you would be assisting Rolls-Royce to adjust and modify were applicable the
spare parts provided for future projects, thereby allowing Rolls-Royce to provide a better and more efficient
service.
1) Were the spare parts received with the main consignment?
2) Were the spare parts easily identifiable from the packing list?
3) Were the spare parts received in good condition?
4) List the spare parts that were used during the Installation and Commissioning, also highlight if these
spares were obtained from either 1) spares provided or 2) by the contacting the Rolls-Royce Project Team.
It may be necessary to make separate lists to provide the information requested, therefore, please attach
it to this questionnaire before returning.
5) Provide information on the lead-time for spares that were supplied that caused a delay to the installation/
commissioning and/or customer dissatisfaction. If necessary continue on an additional sheet of paper.
6) Please use this section to highlight additional information that may assist Rolls-Royce to improve the sup-
ply of Spare Parts at both the front end and as a result of any unforeseen circumstances. If necessary
continue on an additional sheet of paper.
Questionnaire completed by:
Name: Company: Date:
Upon completion, would you please return these questionnaires to the following address:
Rolls-Royce Energy Systems Inc.

105 North Sandusky Street
Mount Vernon
OHIO 43050
United States of America
Attention: ICS Methods Department
391
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Installation and Commissioning Services

Volume 1 Trent - Mechanical and Controls/Electrical Installation Information

Customer: Kenko Bolivia

Proprietary Rights Legend

Chapter 2 - Pre-installation Activities

Section I - - Mechanical Pre-installation Activities

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Activity 17 - Receive and Install Electric Starter Controller Panel . . . . . . . . . . . . . . . . . . . 83

Chapter 3 - Installation Activities

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Activity 52 - Fire and Gas System Interconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Chapter 4 - Electrical activities

Chapter 5 - Safety method statement

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Fire and gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Chapter 6 - Risk assessment

Chapter 7 - Engineering standards

Chapter 10 - Spare parts list

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America’s Region Operators

Asia Pacific Region Operators

Middle East Region Operators

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Activity 1 - Receiving the Gas Turbine/

Receiving and Inspecting

Note: Once the inventory has taken place, any subsequent

e) Free from vermin or insect invasion.

Activity 2 - Receiving the Trent Gas

observed as outlined in Rolls-Royce Engineering

Activity 3 - Receiving the A/C Generator

After removing the packing cases from the transport

information, refer to chapter "Engineering Standards,

11) Store the equipment in an area that provides the

Activity 4 - Receiving the Combustion

After removing the packing cases from the transport

information, refer to chapter "Engineering Standards,

11) Store the equipment in an area that provides the

Activity 5 - Receiving Gas Turbine

Note: The Gas Turbine Enclosure roof sections are

Project Team in Mt.Vernon and will arrange for

5) Confirm that all boxes shown on packing lists have

Activity 6 - Receiving Gas Turbine

maintain an inventory, as well as warehouse records and

drawings for periodic inspection requirements. Record and

c) Easy access for inspection and/or service.

Activity 7 - Receiving Bleed (BOV)

responsibility to off load and store the equipment, to

drawings for periodic inspection requirements. Record and

c) Easy access for inspection and/or service.

Activity 8 - Receiving Exhaust

1) Within 14 days of the equipment arriving at site, a full

the Project Manager will arrange to charge the customer

12) Photograph all damage. If necessary, return damaged

Activity 9 - Receiving Gas Turbine /

1) Within 14 days of the equipment arriving at site, a full

the Project Manager will arrange to charge the customer

12) Photograph all damage. If necessary, return damaged