20240909IPC to Staff 94(e) - Attachment 5 - HCPR190001 UNIT 2 Commissioning HCPR GOVERNOR COMMISSIONING UNIT 2_COMPLETED.pdf

HCPR UNIT #2 GOVERNOR COMMISSIONING
INITIAL STARTING
1. REMOVE ALL ASSOCIATED LOTO DEVICES FROM ELECTRICAL,
PNUEMATIC, AND HYDRAULIC SYSTEMS FOR GOVERNOR.
2. VERIFY GOVERNOR OIL PUMPS ARE IN MANUAL ON THE HMI.
3. VERIFY GOVERNOR OIL PUMPS ARE IN THE OFF POSITION ON THE
SWITCH.
4. VERIFY GATE LOCK IS IN THE RELEASED POSITION WITH THE
VALVES AT MANIFOLD.
5. VERIFY VALVES ON HYDRAULIC MANIFOLD ARE IN THE CORRECT
POSITION.
5a. MAN. LOCK RETRACT (CLOSED).
5b. MAN. LOCK EXTEND (OPEN).
5c. POPPETS CLOSE (OPEN).
5d. POPPETS OPEN (CLOSED).
6. VERIFY GOVERNOR IS IN MAINTENANCE MODE.
7. YOU WILL HAVE TO FORCE SOME POINTS FOR THIS.
8. VERIFY ESD-A AND ESD-B ARE IN THE MANUAL MODE.
9. VERIFY ESD-A AND ESD-B ARE ENERGIZED.
10. VERIFY PROP VALVE HAS VOLTAGE AND CORRECT mA
SIGNAL.
11. VERIFY PROP VALVE IS IN PROP VALVE OFFSET MODE.
12. VERIFY ALL TRIP JACKS FOR 86N/94G ARE DISABLED IN THE
PLC.
13. VERIFY UNLOADERS ARE OPERATIONAL BY PULLING
PLUNGER ON RELAY'S IN RIO CABINET.
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14. TURN PILOT OPERATED CHECK VALVES ALL THE WAY IN TO
DEFEAT THEM. THIS WILL ALLOW OIL TO THE PROP VALVE AT
PRESSURE BELOW 160 PSI.
OIL PRESSURIZATION
1. TURN PILOT OPERATED CHECK VALVES IN TO DEFEAT THEM
2. START GOVERNOR OIL PUMPS IN MANUAL AND PUMP OIL INTO
THE ACCUMULATOR TANK.
3. VERIFY GAT TRANSDUCER IS READING, BRING UP TO 24 INCHES
4. MANUALLY STOP PUMPS.
5. AFTER WE HAVE COME UP IN PRESSURE, BLEED ALL PRESSURE
TRANSDUCERS.
6. AFTER PUMPS HAVE MOVED OIL INTO GAT, FILL WITH AIR TO
ACHIEVE OIL PRESSURE OF 90 PSI.
7. VERIFY TRANSDUCERS HAVE BEEN BLED.
8. DO A QUICK NULL OF PROP VALVE, THIS WILL NEED DONE AGAIN
AT 300 PSI.
9. USE PROP VALVE OFFSET TO MOVE OIL TO AND FROM SERVOS.
10. BLEED AIR FROM SERVO'S AS PER WOODWARDS
PROCEDURES.
11. WATCH OIL LEVEL IN GOVERNOR ACCUMULATOR TANK, FILL
AS NEEDED TO MAINTAIN OIL LEVEL. PUMPS WILL BE IN MANUAL
CONTROL.
12. CHECK ALL FITINGS AND FLANGES FOR SIGNS OF LEAKS.
13. AFTER GATES HAVE BEEN STROKED 5-6 TIMES, WE CAN
INCREASE PRESSURE AND REPEAT.
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INCREASE PRESSURE TO 200 PSI
1. USING PROP VALVE OFFSET MODE, MOVE DISTRIBUTING VALVE
OPEN AND CLOSED 5-6 TIMES.
2. OPEN GATES FULLY, AND CENTER YOUR PROP VALVE WITH 12mA.
3. FULLY OPEN GATES AND APPLY POPPETS.
4. TURN PILOT OPERATED CHECK VALVES OUT TO RETURN THEM TO
NORMAL
INCREASE PRESSURE TO 300 PSI
1. WE WILL RELEASE POPPETS AND SET OUR NULL POSITION WITH
THE LVDT.
2. INSTALL A DIAL INDICATOR ON THE DISTRIBUTING VALVE TO HELP
WITH CENTERING OF PROP VALVE.
3. PUT WICKET GATES AT 50% WITH PROP VALVE OFFSET MODE,
AND CENTER YOUR PROP VALVE AT 12mA.
4. RELEASE POPPETS TO START SETTING NULL POSITION.
SETTING NULL
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1. WHEN POPPETS ARE RELEASED, WATCH MLDT FOR GATE
MOVEMENT. ADJUST LVDT UP OR DOWN TO GET NULL ON PROP
VALVE. THIS ADJUSTMENT TAKES SOME TRIAL AND ERROR. YOU
NEED TO OBSERVE THE DIAL INDICATOR AND MAKE SMALL
ADJUSTMENTS TO ACHIEVE.
2. THIS WILL BE 12mA TO PROP VALVE. VERIFY NO GATE
MOVEMENT AND APPLY YOUR POPPETS SO GATES WILL NOT
MOVE.
PROP VALVE OFFSET TO STOP NUTS
1. WE WILL START RECORDING DISTRIBUTING VALVE MOVEMENT
AND mA SIGNAL.
2. USING PROP VALVE OFFSET MODE, OFFSET PROP VALVE TO THE
OPEN POSITION. OBSERVE MOVEMENT ON THE DISTRIBUTING
VALVE. KEEP ADJUSTING UNTIL THE DISTRIBUTING VALVE MAKES
CONTACT WITH THE STOP NUTS OBSERVING THE PRESSURE
GAUGES AND DIAL INDICATOR MOVEMENT. RECORD mA VALUE,
DIAL INDICATOR READING, AND PRESSURE READING ON GAUGES.
3. UPPER SETTING IS: 15.52 mA
4. USING PROP VALVE OFFSET MODE, OFFSET PROP VALVE TO THE
CLOSED POSITION. OBSERVE MOVEMENT ON THE DISTRIBUTING
VALVE. KEEP ADJUSTING UNTIL THE DISTRIBUTING VALVE MAKES
CONTACT WITH THE STOP NUTS OBSERVING THE PRESSURE
GAUGES. RECORD mA VALUE, DIAL INDICATOR READING, AND
PRESSURE READING ON GAUGES.
5. LOWER SETTING IS: 8.01 mA
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6. FIND YOUR HIGHEST mA READING ON THE FULL OPEN OR FULL
CLOSED STROKE OF THE DISTRIBUTING VALVE. WE WILL PUT THIS
READING PLUS 1-2 mA INTO THE GOV COMMISSION PARA.
7. AFTER YOU HAVE ACHIEVED NULL, RECORDED ALL THE VALUES
AND MADE CHANGES IN THE PLC.
PUMP LEAD/LAG CHECKOUT
1. PLACE PUMP A IN AUTO AND LAG.
2. OPEN DISCONNECT ON PUMP B TO REMOVE 480 POWER,
MANUALLY PULL THE UNDERVOLTAGE RELAY TAB SO PLC THINKS
PUMP B IS OK.
3. PLACE PUMP B IN AUTO AND LEAD.
4. MOVE GATES WITH PROP VALVE OFFSET.
5. VERIFY PUMP B TRIES TO START FROM THE OUTPUT RELAY.
6. WHEN PUMP B FAIL COMES TRUE, PUMP A WILL BE MOVED TO
LEAD AND START.
7. CLEAR ALARMS AND PUT PUMP B BACK IN LEAD.
8. MOVE GATES TO GET PUMP B TO START AT 270.
9. AS SOON AS PUMP B OUTPUT RELAY GOES HIGH, MANUALY PUSH
STARTER SO THE PLC THINKS PUMP B IS RUNNING. AFTER 120
SECONDS YOU WILL GET A PUMP OVER-RUN ALARM.
10. CONTINUE MOVING GATES UNTIL THE LAG PUMP STARTS
AND VERIFY IT PUMPS TO 300 PSI.
11. RETURN PUMP B UNDERVOLTAGE RELAY TO NORMAL AND
CLOSE DISCONNECT.
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AUTO BLOW DOWN
1. MOVE OIL AROUND TO ARM BLOW DOWN.
2. VERIFY BLOW DOWN IS ARMED: 32 INCHES
3. VERIFY BLOW DOWN BEGINS AT: 275 PSI
4. VERIFY OUTPUT TO OTHER UNITS TO BLOCK BLOWDOWN.
5. VERIFY INPUTS AT OTHER UNITS.
6. USING OUTPUT RELAY OF OTHER UNITS, VERIFY BLOCKING INPUT.
GOVERNOR ALARMS AND TRIPS
1. STARTING GOV OIL PUMPS IN MANUAL, PUMP OIL INTO GAT AND
OBSERVE THE LEVEL WHEN THE HIGH-ALARM, HIGH/HIGH TRIP
AND GOV OIL PUMP CUTOUT COME IN.
2. HIGH ALARM IS SET AT: 34 INCHES
3. HIGH/HIGH TRIP IS SET AT: 36 INCHES
4. GOV OIL PUMP CUTOUT IS SET AT: 1 INCH IN SUMP. VERIFY
PUMP UNLOADS AND SHUTS OFF.
5. TURN GOV OIL PUMPS TO OFF.
6. VERIFY SHUTDOWN SPEED ADJUSTMENT IS SET TO 1 TURN OUT.
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7. RELEASE POPPETS AND MOVE GATES WITH PROP VALVE OFFSET
MODE.
8. CONTINURE TO STROKE GATES UNTIL THE LOW-LEVEL ALARM
AND LOW-LOW TRIP COME IN.
9. LOW LEVEL-ALARM IS SET TO: 1 20 INCHES
10. LOW-LOW TRIP IS SET TO: F121NCHES
11. AT TH E LOW-LOW TRI P. AN D WITH GATES AT 100% PU LL
POWER CONNECTOR FROM ESD-A AND WATCH GATES COME
SHUT.
12. RE-CENTER PROP VALVE.
13. MANUALLY START PUMPS AND BRING OIL LEVEL AND
PRESSURE TO NORMAL OPERATIONS.
14. MOVE GATES TO GET TO 240 PSI LOW-LOW PRESSURE TRIP.
15. AT THE LOW-LOW TRIP, AND WITH GATES AT 100%, PULL
POWER CONNECTOR FROM ESD-B AND WATCH GATES COME
SHUT.
16. WITH GOVORNER IN MAINT MODE, POPPET WICKET GATES.
WE WILL UNPLUG THE FOLLOWING CONNECTORS TO SEE WHAT
THE DISTRIBUTING VALVE DOES.
16a. PROP VALVE MAIN POWER AND SIGNAL CONNECTOR.
16b. PROP VALVE POSITION mA SIGNAL TEST JACK.
16c. PROP VALVE LVDT CONNECTOR.
16d. ESDA CONNECTOR.
16e. ESDB CONNECTOR.
17. VERIFY MLDT ALARMS AND TRIP.
17a. MLDTA CONNECTOR.
17b. MLDTB CONNECTOR.
17c. BOTH MLDTA AND MLDTB CONNECTOR.
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GATE CUSHION TEST
1. USING MAINT GATE SET POINT MODE, MOVE GATES SLOWLY TO
85%. FROM 85% MAKE A MOVEMENT TO 95% AND VERIFY GATE
LIMITER STARTS AT 90%, THIS WILL SLOW YOUR GATES DOWN
AND NOT ALLOW THE SERVO PISTON TO HIT THE HOUSING.
2. WE CAN NOW MAKE A 85% TO 100% GATE MOVEMENT.
3. MOVE GATES SLOWLY DOWN TO 25%. FROM 25% MAKE A
MOVEMENT TO 2%, THE CUSHION SHOULD START AT AROUND
9% AND SLOW YOUR GATES DOWN AND NOT ALLOW THE SERVO
PISTON TO HIT THE HOUSING.
4. WE CAN NOW MAKE A 25% TO 0% GATE MOVEMENT.
DRY GOVERNOR TUNING
1. USE THE DAQ BOOK FOR THIS PROCESS.
2. INSTALL OUR TEST LVDT.
3. RUN WIRE FROM DAQ BOOK TO 1 OF OUR MLDT'S FOR GATE
FEEDBACK.
4. VERIFY SETTINGS IN YOUR GOV_PARA.
5. CHANGE THE MAINTENANCE MODE LIMITER SO WE ARE NOT
LIMITING THE PROP VALVE.
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6. WE WILL START WITH THE FINAL TUNING NUMBERS FROM THE
PREVIOUS UNIT.
7. WE HAVE TRENDS FROM PREVIOUS UNITS, USE THESE TO DO THE
INITIAL TUNE OF THE GOVERNOR IN THE DRY.
8. % K IS A GOOD RULE OF THUMB FOR PID TUNING.
9. P = 15
10. 1 = 50s
WICKET GATE TIMING TEST
1. ORIGINAL 80%-30%: 3.00
2. ORIGINAL 100%-0%: 9.7
3. ORIGINAL GATE CUSHION: 4.1
4. WE WILL USE DAQ BOOK FOR RECORDING.
5. MOVE GATES BACK TO 100% OPEN TO START OUR GATE TIMING
TEST. WE WILL BE TESTING THE PROP VALVE AND ESD'S.
6. SET UP IN THE PLC YOUR PARAMETERS FOR THE PROP VALVE
TIMING TEST.
7. START PROP VALVE TIMING TEST, GATES WILL MOVE FROM 100%
TO 0%. TEST WILL RECORD YOUR TIME FROM 80% TO 30%. VERIFY
ON DAQ BOOK THE 100% TO 0% TIME, AND GATE CUSHION.
THESE TIMES SHOULD MATCH ORIGINAL COMMISSIONING
DOCUMENTS.
8. MOVE GATES BACK TO 100%
9. POPULATE PARAMETERS IN THE ESD TIMING TEST.
10. TURN YOUR SHUTDOWN SPEED ADJUST #27 VALVE IN TO
FULL CLOSE, AND BACK OUT: 1TURN THIS WILL BE THE
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STARTING POINT TO GET THE CORRECT GATE TIMING WITH THE
ESD'S.
11. START ESD TIMING TEST, GATES WILL MOVE FROM 100% TO
0%. TEST WILL RECORD YOUR TIME FROM 80% TO 30%.
12. IF THE ESD TIMING TEST IS TOO SLOW, YOU WILL HAVE TO
BACK OUT THE SHUTDOWN SPEED ADJUST VALVE AND TEST TO
UNTIL YOU REACH THE CORRECT TIMING.
13. AFTER YOU RUN BOTH OF THESE TEST'S, YOU NEED CHANGE
THE MAINT MODE LIMITER SETTING. YOU WILL SET THIS LIMITER
TO A RATE OF: 18SECONDS FROM 80% TO 30%, THIS WILL
MATCH ORIGINAL COMMISSIONING DOCUMENTS.
14. PROP VALVE 80%-30%: 3.3
15. PROP VALVE 100%-0%: 9.5
16. ESD 80%-30%: 3.00
17. ESD 100%-0%: 9.6
18. ESD SHUTDOWN SPEED ADJUST VALVE SETTING: 1 TURNS OUT
19. GATE CUSHION: 10% (cD 4S
SSG TEST STAND
1. VERIFY POPPETS ARE APPLIED, WE DON'T WANT TO MOVE GATES.
2. WIRE SPEED PROBES TO SPEED CARD.
3. START TEST STAND TO VERIFY SPEED PROBES ARE CORRECT.
4. TEST OVERSPEED TRIP AND RESET.
5. TRIP IS 125%
6. RESET IS 105%
7. RELEASE POPPETS.
8. MOVE GATES TO 2%.
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9. USING AN ANALOG OUT CHANEL SET TO 0-10 VOLTS, WIRING TO
THE VFD ON THE SSG TEST STAND. THIS WILL LET US RAMP THE
SSG FROM 0 RPM TO 120 RPM WHEN WE GIVE THE PLC A GOV
RUN.
10. GATE LIMIT SHOULD AUTO POPULATE AT 25 AS A CUSHION
SO WE DO NOT GO FULL GATE IF SOMETHING IS WRONG.
11. FORCING GOV RUN HIGH, WATCH THE SSG START AND
GATES TO COME OPEN, WHEN SSG IS AT SYNC SPEED THE GATES
SHOULD STOP MOVING. IF YOU KEEP THE GATES HERE AND DO
NOT MAKE ANY CHANGES, THEY WILL START TO SLOWLY CREEP
OPEN BECAUSE OF THE 55mHZ SLIP FREQUENCY.
12. WITH THE SSG TEST STAND, MAKE SPEED CHANGES TO
SLOW IT DOWN AND WATCH GATES OPEN, THEN SPEED UP TO
WATCH GATES CLOSE.
GATE LOCK
1. ORIGINAL RELEASE: 1 2.5
2. ORIGNAL APPLY: 6.5
3. CLOSE WICKET GATES AND VERIFY PLC APPLIES SQUEEZE.
4. OPERATE WICKET GATE LOCK TO THE LOCK POSITION.
5. TIMING GATE LOCK MOVEMENT, RELEASE GATE LOCK.
6. TIMING GATE LOCK MOVEMENT, APPLY GATE LOCK.
7. GATE LOCK RELEASE VERIFIED: 2.8
8. GATE LOCK APPLY VERIFIED: 6.2
9. WITH GATES CLOSED AND GATE LOCK APPLIED, VERIFY 0%
CLOSED SWITCH IS ADJUSTED CORRECTLY.
10. ZERO MLDT WITH SQUEEZE APPLIED
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BRAKES
1. VERIFY BRAKE VALVE POSITION
2. BYPASS WILL BE OPEN TO SET BRAKES
3. SUPPLY AND DISCHARGE WILL BE CLOSED
4. CLOSE BYPASS
5. OPEN SUPPLY AND DISCHARGE
6. OPERATE BRAKES WITH OUTPUT RELAY FROM PLC
7. VERIFY BRAKE INDICATION
8. VERIFY BRAKE MISOPERATION PRESSURE SWITCH IS CORRECT
9. CYCLE BRAKES TO VERIFY OPERATION.
10. WE WILL VERIFY BRAKE OPERATION WITH A CREEP BEFORE
PUTTING THEM BACK IN THE LOTO.
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