BIBLIOGRAPHY

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 1

1. IntroductioDI
This ~hedule covers the site tests for Mechanical parts of 3 x 8.5MW
DielMtl Generating Plant for ZHONGSHAN' POWER STJ.TIOI.
The site tests inolude the initial adjustments, the pre-commissioning tests
and the commissioning tests.

,• 2. Outline flow of the sit. tests;

The tests flow shall be as follows:

~- .
, ' I ,. I

Completion Finishing Initial Pre-Commissioning

of works adjusting works tests
flushing for (Preliminary tests)
lub. oil &:
tuel oil system

*
.
Taking Over
,
Commissioning
.
10 load
Certificates tests tests

* The Taking Over Certifioates shall be issued within one week after the
the satisfactory on the 4&7 of each engine-generator set will be
successfully commissioned and tested by the Client.

3. Initial adjustment (Preliminary tests):

The following tests and confirmations shall be oarried out prior to
the pre-commissioning tests.,

1) Adjustment and testing of all protective devices, suoh as overspeed

deteoting devioes, pressure switches, tem~rature SWitches, level
switches eto.

I The Betting figure of each protective device is shown on" Section 4".

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 (2

The tests procedures shall be carried out in accordance with the

following chart.

500 rpm

,•
Crank case checking
480 I
450 I
400 I
starting 300
350 I
r
Air
running tr) I
1:
a} Local sta:r;.l.ng tests

Speed control for local starting testa shall be performed by

governor knob mounted on each engine.

b) Crank case cheoking

Crank case checking shall be done as follows:

(1) Crank case doors shall not be opened within 15 minutes since
engine has stopped.
(2) Check that there are no foreign substances in the crank case.
(3) Check that each bearing, such as main bearing and conneoting
rod bearing are not over heated.
(4) Bolts for connecting rods are not loosened.
(5) Inner face of each cylinder liner has not discolouration or
scratch.

1 c) Remote starting teats

Each engine shall be started from the remote cont'rol panel by turning
MCS (Master Control Switch) to "ENGINE START" po a! tion and following
time and engine revolution shall be measured and reoorded.

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Ishllcawajima- Hatima Heavy Industries CO' t Ltd.

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 ,3

ttl1 nNll

I
t1sec. t2 sec.
r----...L.~:..,.~
Position _ _ _ _ .lux. _ _ _ _ _ _ _ Engine
ot MaS start start

• Indication
Larap
r­ ________ Ready for
Engine start

4. Pre-commissioning test:
The follOWing protective device tests shall be carried Qut by the Contractor
under IHI Bupervision and witness by the Client.
The tests records shall be submitted to the Client in triplioate copies
and bear the signatures of the Contractor's representative.

1) Following items shall be done without engine running.

No. I Checking Item Setting Val~ \ Detector . jQHy Light Fault

or
Heavy Paul t

1 Lub. oil preS8ure 0.3 to 0.8 Kg/cJ Pressure 3 Interlocking

switch
2 Jacket cooling fresh pump start cODtaetor 3 Ditto.­
water pump
3 JI'ue 1 oi 1 boostar pump pump at art contaetor 3 Ditto.-
C) 4 Fuel valve cooling fresh
t water pUJIp pwap start contactor 3 DiUo.­
o Raw water pump pump start contactor 3 Ditto.­

Turning device disengage lim t swich 3 nttto.­

7 Governor speed governor 3 Ditto.­

speed knob

8 Valve position of Light 11'.0. limi t awitch 3 Ditto.­

Ligbt F.O./Heavy F.O. position

9 Master control awitch except stop switch 3· nttto.­

position POI!it ion
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Ishlkawaiima- Hamna Heavy Industries CO' t ltd.

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No. CheckinJ It•• Setting Value Detector Q'ty or
Heavy Fault
10 Boller .eal :l'u tan start oontactor 3 I~terlocJdDg

11 CQOling tower tan fan start conta.ctor 3 Ditto.­

(at least, one fan
is to be started
for each unit. )

ALARM SYSTEM
•
'0

No. Cheoking Item setting Value Detector 'lIt,. Light Fault

or
~. 7.., (j-\ Heavy Fault

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t , " .._

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.
Vi Fuel oil pressure ~cm' pressure 3 Light Fault
switch
-
V" 2 Control air pressure 9.0 ± 0.2 tg/cm2 Ditto.­ 3 Ditto.­
3 Engine Aux. machine
motor fault (common) Ditto.­
I

i '4. Engine outlet jacket

cool'g fresh water 90· ± 2°C therrao- ·3 Ditto.­
high temperature switch

V5 Engine inlet lube oil

high temperature
60'" ± 2"C D1tto.­ :3 Ditto.­

6 Engine outlet jacket 9,± 2"'C Ditto.­ 3 Heavy Fault

cool'g fresh water
high temperature
J
:~ Engine main bearing DittQ.­ 3 Ditto.­
high temperature
8 Oil mist detector lED 15 &: over 3 D1tto.­
.,- 9 Sta.rt failure 10 sec. &: over 3 Ditto.­
10 Fue 1 oil purge (manual) 3 Ditto.­
'.
0­
11 Lub. oil sump tank
low level
1000 :t 50 mm
trom bottom
leve I aw! tch 3 Light Fault

J12 Fresh water expansion

tank low level
400 :t 30 mID
troll bottom
Ditto.­ 1 Ditto.­

13 Rocker arm lube oil 651 t 10 mm Ditto.­ 3 Ditto.­

tank: high' level from bottom
14 Fuel oil drain tank 1080 :!: 50 mID Ditto.­ 1 Ditto.­
high level troll bottom

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Ishllcawallma* Harlma Heavy
. .
Industries CO. I ltd .
 ( 5
Liaht. r'ault
No. Checkin, Item ;jetting Value Det.ector Q'toY or
Heavy }<'ault

15 Heavy fuel oil aery. )000 :t 100 rom limit switch 1 Light .(i'ault
ice tank low level froo bottom
16 Heavy fuel oil sett­ uluO! )0 mm Ditto. ­ 1 Ditto.­
ling tank high level from bottom -
17 Heavy fuel oil aett­ )2uO ! )0 rom Ditto.­ 1 Ditto.­
ling t.ank low level from bottom

• 18 Li5ht fuel oil aerv­

ice tank high level
2uOO ! )0 mm
from bottom
Ditto.­ 1 Ditto.­

19 Light fuel oil aerv­ 1500 ! 30 nun Ditto.­ 1 Dit.to.­

ice tank low level from bottom
level switch 1 Ditto.­
V 20 Lub. oil drain tank
high level
vi080 :! SO mm
from bottom

21 Chemical dosing 100 1: 10 nun electrode J Ditto.­

tank. low level from bottom

22 Feed water tank 1000 1: 30 nun limit switch 1 Ditto.­

~ ...
f,,~911.J,ey~;l,~N from bottom

I
23 boiler water low normal water level level Bwitch 3 Ditto.­
level ..-.
- ( 110 ! 10 mID )
\~.-.---
~.-.-.--.----~.--~

2u Lub. oil purifier "oil leakage lt float switch

abnormal or J Ditto.­
"no opening bowl' limit switch

25 Fuel oil purifier Ditto .... Ditto.­ Ditto.­

abnormal J

26 Heavy fuel oil To be determined level Bwitch 3 Ditto.­

storage tank low level by the Client
-
27 Light fuel oil Ditto ... Ditto.­ 1 Ditto.­
storage tank low level
28 LuQ. oil storage tank Ditto.­ Ditto.­ 1 Ditto.­
low level

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Ishlkawallma- Harlma Heavy Industries Co., Ltd .
 (6 )

2) Following items shall be done with engine running condition.

( No load condition )
Light "ault
No. Checking I tam Setting Value Detector Q't,y or
Heavy Fault

1 Engine inlet lube oil 5.7 ! 0.1 Kg/cm? pressure 3 Light Fault
low pressure (1st) ,
, switch
2 Engine inlet lube oil
~",2.::-.; 0.1 Kg(cm
7
0 low pressure (2nd) .. Ditto.­ 3 Heavy Fault
."

.­ 3 Rocker arm lube oil

low pressure
0.5 ! 0.2 Kg/cut Ditto.­ 3 Light l"ault

4 Over speed (1st:) . ,565 .;. 5 rpm speed relay 3 HeaVy Fault
5 Over speed (2nd) 575 ! 5 rpm mechanical 3 Ditto.­
'-. switch

3) Other checking items:

a. Exhaust gas boiler:

Water level for alarming and feed water pump start/stop shall be checked
under actual condition.

b. Automatic start/stop control for air compressor:

Each compressor shall be run actually and the pre-set value shall be
checked.
c. Automatic start/stop control for pumps:
Following pumps shall be run actuall~ and the pre-set values shall be
checked.
,0 * Fuel oil blow off pump
* Hea~ fuel oil transfer pump
* Light fuel oil transfer pump
 ( .,
4) After the pre-commis8ion~g tes~ tne Contractor shall carry out load
tests for adjustment of engines and generators in accordance with the
following chart.

500. rpm

~Xing 50% 75% \:1.00%

\
110%
Adjustment
\
I
'works
1 hr. 1 hr. \.) hra 1 hr. j
L

5. Commissioning tests:

After the 5atisfactory pre-ca.missioning tests, the cQW~8sionin~ tests

shall be carried out by the Contractor under IHI supervision.
The commissioning tests shall be carried out to prove eatisfacto~ characte­
ristics of the engine-generator sets and auxiliaries. such as governor
performance, synchronizing, loading and so on.

The test items shall be as fOllows: • I

1) ..:ltarting test

2) Loadinl test

(1) 50% Full load run 1.0 hr.

(2 ) 75% Full load run l.() hr.
(3) 100% Full load run 3.0 hrs.
(4) 110% Full load run 1.0 hr.

3) Governor load rejection test

(1) 50% full rejection

(2 ) 75% full rejection

(3) 100% -full rejection

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H ,'J~l't" i'.U·-; ''; -\,.. lIU" Ishikawaiima- Harima Heavy Industries CO. I ltd.
 8

At each load rejection test. followings shall be meas~red.

a) Reading of the load indicator and speed indicator'of the governor

before and after rejection test
b) Engine revolution before and after rejection test
c) Reading of output (KW), current (A). voltage (V), frequency (Hz)
before and after rejection test,
d) Required time for the above variation
"
1 e) Fuel oil pump rack indicator

4) Following items shall be recorded at each load test described in

II 1/
Sec.5-2).
a) Load indicator and speed indicator of the governor
, ~)." Max. cylinder pressure of each cylinder
c) Klaust gas temperature at each cylinder outlet and turbocharger
"
inlet
d) Fuel oil rack
e) Temperature and pressure of raw water, fresh w~ter, injection cooling
fresh water, lube oil, fuel oil, air and exhaust gas
f) Room temperature, ambient temperature. hwniditj', barometric pressure
g) Color of exhaust gas
h) Engine speed
i) TurDocharger rotor speed
j) Performance checking of each auxiliary
k) Output (MW), power factor, current (A), voltage (V), frequency (Hz)
and KW-hour for generator
1) Fuel ollconswnption measurement
o ~ince fuel oil consumption shall be measured in volume and, converted
to weight, the specific &ravity shall be measured.
Three samples of the fuel oil shall be taken and seal, the sample­
bottles.
First sample shall be analyzed by the Client for calCulation of the
fuel oil consumption in accordance with the attached sheet.
In addition to the above analYSiS, second and third samples shall be r
It
analyaeo by third party laboratory and !HI respectively, it the t1

Client orIHI will require these analysises. In this caBe, the •

Ishikawaiima- Harima Heavy Industries Co •• ltd.
 ( 9

average value of the three. samples for calorific value and specific
gravity shall be applied for the final specific fuel oil conaumpitioo
calculation. When excessive fluctuation of the load and the freq­
e
uency on the generators will occure during the mea8~nt of the fuel
oil consumption test, this measurement shall be ineffective and the
fuel oil consumption shall be re-measured during the steady condition.
S) Crank shaft deflection shall be checked at hot condition after
finished commissioning test.
9

i 500 rpm

ISO% 7S% 100% 110% I

I Check the crank shaft
I I
I deflection at hot

/
I
:1 hr. 1 hr. 3 hrs. 1 hr.'
I
condition.
I I

6 Taking over certificates:

The Client shall issue the taking over certificatea within one week after
the satisfactor~ on the day of the each engine.generator set will be
successfully commissioned and tested.

15hikawaiima~ Harlma Heavy ,Industries CO. I Ltd.

 ( 1/1 )

VeaaviDj' ...ulta ot Specific Fuel Oil Consumption

Load 1­ 0, Time Date

Characteristics
, ot used
tDw Calorifio value • Hu • KDal/Xs
hel oil
Specific Gravity 15/4 (Ie o•
•
~
Q)

I
ICw-h Meter Time DI-h/h

,.
'.
Readings Readings (j)':-®
Generator End
i
Output
Start '. .
'"

Q) ®
.
(End)-(Start ) XW-h hr
,

~ ~
Q)
Time
~+" Liter
, .,-1 (I) Readings
~'d .
filH End
~
H Start ,
....
G)

~
'.
~
0 (End)-(Start ) ® G> hr'
.,-1

~ rot (G
g ~ FUel 'remp. CO Corrected 5.0.

= End
~
0
0

.........0
....~
.....
()

c::
start
~
~,
.-t 0
~QJ
........
CD
l (End)-(Start) Liter

I
.t! g
l...:.:!
~~
....,
J"uel 'romp. °c Correct.d s.a. ®
Con8UIDption Xg @
(@X®) - «7)x <B> ) - a (see note)
19
'Correoted Consumption Xg/h ~+G>

~I
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..... .,-1
=
0 f.8./JfJII-h @+(j)
'~ ....p.
~
JZ,.
11.1
....
()

.... 0=
Ct-1
()
0
Correoted value baaed on 10.200 KDal/Xg
C> .....
.,... Hu
p.
rn 0 Ox 1(5,200' Xg/Xw-h
Hote. During the fuel oil conaumption test ,lea.Jcase oil fJ'911 drain pipes
ehall be Masured t and the fuel oil consumption shall be corrected.
( G ) in Kg ~ W€isht of leaked. ,,: I
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