GCU TESTING

a. Purpose
This test is carried out to demonstrate satisfactory performance of gas combustion unit.

b. Preparation
1. GCU, air fans, gas valve train (GVT), and associated accessories should be installed properly.
Integrality and tightness test for fuel gas and control air piping system should be
completed.

2. Safeties shall be checked and working in normal.

3. Electric cables, loop running fields site and serial / hardwired I/O Exchange with IAS should
be completed.

4. Safeties check as follows shall be completed.

1) Gas inlet pressure transmitter
2) Gas inlet temperature transmitter
3) Pressure transmitter for chamber pressure
4) Exhaust gas temperature
5) Compressed air pressure switch
6) UV scanner
7) Fan motor winding temperature

5. Igniters check
Sparks can be checked:
- by visual inspection through the view port
- or by checking the flame signal in control cabinet
- or by checking the flame level indicator inside flame relays (in control cabinet)

6. Gas valve train check

Before use of GVT, check that all sensors manifolds are in normal position and all manual
valves are opened.

c. Procedure
1. GCU starting test
- Local operation: the GCU is driven exclusively locally by the operator with push buttons in
front of the cabinet.
- Remote operation: the GCU is driven exclusively by inputs from IAS. However, the operator
must switch the GCU in "Remote" position on the front of the control cabinet.
Prior to any ignition, the air purging will be obtained 30s after at least 2 fans are running. This
will ensure that the combustion chamber and the exhaust stack do not contain any unburned
gas when the burner will be started. This delay is internally checked by the GCU control system.

2. Capacity test
Increase capacity from min. to max. gas flow, keep stable running at full load for one (1)
hour, print data record from IAS.

3. GCU shutdown test

(1) GCU voluntary stop test
- Local operation: from the control cabinet by pressing “STOP BURNER” push button.
- Remote operation: automatically from IAS by opening “Select stop mode” contact
(pulse).
(2) Local emergency shutdown test
After active emergency shutdown in local, GCU shall immediately stop and fans
automatically stop.

4. Full Free flow test

Stop Low Duty Compressors, gas heater ready and heat BOG to suitable temperature, gas
pressure to be higher than 100 mbarg at Gas Valve Train inlet, GCU free flow rate shall be
tested during gas free operation.
GCU shall keep stable running for one hour. Then print data record from IAS.

5. Gas trip test（external safety）

(1) Gas detection in GVT room/ air fans room
(2) Fire alarm
(3) Both GVT room exhaust fans failure
(4) Master valve on BOG supply pipeline closed

If above mentioned situation happened, alarm or safety signal shall be displayed on

Control Panel, GCU to be shutdown automatically and Master valves on BOG pipeline to be
closed.

6. GCU operation mode demonstration

- Normal gas mode
- Tank warming mode
- Free flow mode
d. Record table
No. Item Result
Local operation
1) GCU starting test
Remote operation
Min. flow rate: kg/h
2) Capacity test
Max. flow rate: kg/h
GCU voluntary stop test
3) GCU shutdown test
Local emergency shutdown test
Gas inlet temp.: degC
4) Full Free flow test Gas inlet press.: mbarg
Free flow rate: kg/h
Gas detection
Fire alarm
Gas trip test (external
5) Exhaust fans failure
safety)
Master valve on BOG gas supply
pipeline closed