Vol 2

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Installation and Commissioning Services

Manual (ICS Manuals)
Volume 2 Trent - Mechanical and Controls/Electrical Commissioning Information
Revision Level: 0
Customer: Kenko Bolivia
M.A606.01
GED00240683
Export Controlled
This document contains 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.
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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-commissioning Activities

Chapter Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section I Introduction: Mechanical Pre-commissioning Activities . . . . . . . . . . . . . . . . . . . . 17
Activity 79 - Earthing / Grounding Integrity Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Activity 80 - Verify operation of Customer AC/DC Power Distribution and Uninterrupted
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Activity 81 - Wire Check and Power-up Package AC Power Lighting . . . . . . . . . . . . . . . 27
Activity 82 - Wire Check and Power-up Package Emergency Lighting . . . . . . . . . . . . . . 29
Activity 83 - Wire Check and Power-up Unit Control Panel . . . . . . . . . . . . . . . . . . . . . . . 31
Activity 84 - Wire Check and Power-up GT Enclosure Panel . . . . . . . . . . . . . . . . . . . . . 33
Activity 85 - Wire Check and Power-up Generator Monitoring Panel . . . . . . . . . . . . . . . 35
Activity 86 - Wire Check and Power-up GT Electric Starter . . . . . . . . . . . . . . . . . . . . . . . 37
Activity 87 - Wire Check and Power-up Fire and Gas System . . . . . . . . . . . . . . . . . . . . 39
Activity 88 - Power-up Main Control Room HMI (FT-210) and establish communication 41
Activity 89 - Establish Control Net, Device Net and Ethernet Communications . . . . . . . 43
Activity 90 - Motor Control Center Functional Test (by others) . . . . . . . . . . . . . . . . . . . . 45
Activity 91 - Generator DC Lube Oil Control Functional Test. . . . . . . . . . . . . . . . . . . . . . 47
Section I Introduction: Mechanical Pre-commissioning Activities . . . . . . . . . . . . . . . . . . . . 51
Activity 92 - Check Customer Connections for the A/C Generator Lube Oil System. . . . 53
Activity 93 - Check Rolls-Royce Connections for the Inlet Air System . . . . . . . . . . . . . . 55
Activity 94 - Check the Correct Installation of the Vent Fans . . . . . . . . . . . . . . . . . . . . . . 57
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Activity 95 - Check Customer Connections for A/C Generator Lube Oil Cooling System . 59
Activity 96 - Check Customer Connections for GT Cooling Water System . . . . . . . . . . . . 61
Activity 97 - Gas Fuel Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Activity 98 - Check Customer Connections for All Drains . . . . . . . . . . . . . . . . . . . . . . . . . 67
Activity 99 - Check All Electric Pump Rotations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Activity 100 - Check All Fan Rotations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Activity 101 - Inspect, Clean and Fill the A/C Generator Oil Reservoir . . . . . . . . . . . . . . . 73
Activity 102 - Inspect, Clean and Fill The Gas Turbine Oil Reservoir . . . . . . . . . . . . . . . . 77
Activity 103 - Blow Down Gas Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Activity 104 - Clean and Inspect the Combined Gas Turbine Air Intake System . . . . . . . 83
Activity 105 - Clean and Inspect the Gas Turbine Air Inlet Plenum. . . . . . . . . . . . . . . . . . 87
Activity 106 - Inspect and Flush the Package Gas Turbine Air Service System . . . . . . . . 89
Activity 107 - Flush the Gas Turbine Oil System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Activity 108 - Flush A/C Generator Lube Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Activity 109 - Flush the Gas Turbine Cooling Water System. . . . . . . . . . . . . . . . . . . . . . . 95
Activity 110 - Flush A/C Generator Lube Oil Cooling Water System . . . . . . . . . . . . . . . . . 99
Activity 111 - Blow Down and Leak Test CO2 System . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Activity 139 - Restore Gas Turbine Lube Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Activity 140 - Restore Gas Turbine Lube Oil Cooling Water system . . . . . . . . . . . . . . . . . 105
Activity 141 - Restore A/C Generator Lube Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Activity 142 - Restore A/C Generator Lube Oil Water Cooling System. . . . . . . . . . . . . . . 109
Chapter 3 - Commissioning Activities

Section II Introduction: Controls/Electrical Pre-commissioning Activities . . . . . . . . . . . . . . . 115
Activity 143 - Instrumentation Calibration and Loop Checks. . . . . . . . . . . . . . . . . . . . . . . 117
Activity 144 - Generator Protection Relay Calibration and Secondary Current Injection Test
119
Activity 145 - Engine Geometry Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Activity 146 - Oil Quantitative Debris Monitoring System Test and Calibration Procedures
123
Activity 147 - Gas Turbine Gas Fuel Valve Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Activity 148 - Gas Detector Calibration and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Activity 149 - Multi-Spectrum Flame Detector Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Activity 150 - Functional Testing of Horns, Strobes, and Release Devices . . . . . . . . . . . . 131
Activity 151 - Ignition Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Activity 152 - Test and Set Panel Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Section I Introduction: Mechanical Commissioning Activities. . . . . . . . . . . . . . . . . . . . . . . . 143
Activity 154 - Generator Direct Air Cooling DAC Testing . . . . . . . . . . . . . . . . . . . . . . . . . 145
Activity 155 - GT (AAF) Pulse Air Cleaning System Test . . . . . . . . . . . . . . . . . . . . . . . . . 147
Activity 156 - GT Control Oil System Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Activity 157 - GT Electric Starter Motor Cooling System Function Test. . . . . . . . . . . . . . . 151
Activity 158 - Generator Lube Oil Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Activity 159 - Generator DC Lube Oil Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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Activity 160 - Compressor Water Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Activity 161 - Emergency Shutdown Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Activity 162 - Start-Up Sequence Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Activity 163 - CO2 Dump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Activity 164 - Engine Crank Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Activity 165 - Gas Fuel Gas Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Activity 166 - Prior to First Fire (starting unit for first time). . . . . . . . . . . . . . . . . . . . . . . . 169
Activity 167 - Start on Gas Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Activity 168 - Package Hot Commissioning Off-Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Activity 169 - Perform Generator On-Line Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Activity 170 - Perform Generator Off-Line Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Activity 171 - Package Hot Commissioning On-Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Activity 172 - Fuel Transfer Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Activity 173 - Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Activity 174 - Perform CO2 and NOX Emission Verification Test . . . . . . . . . . . . . . . . . . 187
Activity 175 - Statement of Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Chapter 4 - Safety method statement

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Electricity - above 240v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Electricity - up to 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Electricity - ignition system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Synthetic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Motor rotation checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Pressure testing with nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Working with restricted access / obstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Fire and gas system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Preparation for engine crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Initial crank of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Washing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Hazardous atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Test schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Chapter 5 - Risk assessment

Assessment with existing control measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Assessment of risk reduction actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Guidance on completion of risk assessment form . . . . . . . . . . . . . . . . . . . . . . . . . 219
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Chapter 6 - Engineering standards

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Engineering standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Gas turbine engineering requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Gas turbine engineering specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Miscellaneous documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Chapter 7 - Forms
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Chapter 8 - Drawings
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Project drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Chapter 9 - Spare parts list
Chapter 10 - Questionnaire
Installation and commissioning manuals questionnaire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Questionnaire on spare parts provided for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 245
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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 con-
ditions.
• 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

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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.
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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-
commissioning
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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Section I Controls Pre-
commissioning
Activities
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Section I Introduction: Mechanical Pre-

commissioning Activities
The following mechanical pre-commissioning activities are arranged sequentially and should be followed in con-
secutive order. All mechanical pre-commissioning activities must be completed before proceeding to Section II
Controls/Electrical Pre-commissioning Activities.
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INSTALLATION AND COMMISSIONING ACTIVITY SHEET
KENKO BOLIVIA - M.A606.01
Completed Witnessed
Work Description By By Date
Activity 79 - Earthing / Grounding

Integrity Test
Referenced Documents
GED00160539 - Generator Monitoring Panel General
Arrangement
GED00220839 - ECS/SIS/PCS UCP Control Panel
Schematic
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 0018 - Package Wiring System Engineering and

Installation Specification
GER 0035 - Rolls-Royce Energy Customer Guidelines for
Cross Site Wiring
GER 0070 - Grounding / Earthing Design and Application
Instructions Notes
1) This commissioning procedure is authorised for use by
suitably qualified personnel.
2) All the steps taken in this procedure are to be carried
out sequentially unless otherwise instructed.
Comments
Signatures / Date
Print Name Signature
Customer
Rolls-Royce
19
Completed Witnessed
3) In the event that a step cannot be completed, the

procedure should be stopped, the system made safe,
and supervisory staff informed.
4) Any irregularities or discrepancies found in this
procedure are to be brought to the attention of the
supervisory staff so that the problem can be resolved
and the document revised to incorporate any
modifications or changes.
5) Ensure that all of the drawings are of the latest issue.
For more information, refer to chapter "Engineering
Standards, Forms, and Drawings."
Instructions
1) All grounding bonds and cross bonds are to be
complete from the ground mat to the various
structures (GT, generator, control room, auxiliary
equipment, steel bases, and also columns adjacent to
the GT package).
2) All bonding and cross bonds between the package
enclosures and base plates are to be complete.
3) All grounding bonds to the MCC, UPS, PCS, GMP,
GCPI, auxiliary equipment, and control panels are to
be complete using the Rolls-Royce drawings listed
above. For more information, refer to chapter
"Engineering Standards, Forms, and Drawings."
4) All connections to the instrument and clean earth bars
are to be completed and connected to the station earth
system.
Comments
Signatures / Date
Customer
Rolls-Royce
20
Completed Witnessed
5) All extraneous steelwork cable trays, uni-strut, junction

boxes, etc., are to be bonded and cross bonded.
Instrument Clean Earth Tests

1) 1) Remove the main earth connection at the
instrument earth bar.
2) 2) Connect a multimeter, selected to ohms, between
the main earth (dirty earth) cable and the removed
main earth cable/connection, from the instrument bar.
3) 3) Measure the resistance between instrument earth
bar and the main earth. If the readings are below 100
K?, remove, one by one, the sub-distributed
connections at the earth bar, with the meter connected
to each sub earth removed and main earth, monitor
the meter readings, rectify and record below the
reasons for the low reading.
Panel Reason for Action Reading

low reading taken
Comments
Signatures / Date
Customer
Rolls-Royce
21
Completed Witnessed
4) 4) Continue until the overall readings are greater than

10 M?.
5) 5) When the overall readings have been achieved;
reconnect all ground cable disconnections, including
the main earth conductor, to the instrument earth bar.
Main Earth Continuity Tests
1) 1) From a site produced drawing / sketch identify the
earth points to be tested, use a matrix to record the
positions and test results, for example A-B=0.01?.
2) 2) Connect between each earth point or structure a
low resistance tester that can measure micro/
milliohms (100 amp ohmmeter / test equipment).
3) 3) Inject each earth point, recording the results,
ensuring the reading are less than 1?, on the primary
connections to the earth mat.
Comments
Signatures / Date
Customer
Rolls-Royce
22
Completed Witnessed
Note: Less than 0.5? would be more desirable for the

above step.
4) 4) If high readings are found, investigate, clean the
connections, and install more conductors to achieve a
reading less than 1?.
5) 5) Check each panel instrument earth, panel earth to
main earth, and record the results below.
Test Points Results Comments Date
Comments
Signatures / Date
Customer
Rolls-Royce
23
Completed Witnessed
6) On completion of tests, ensure that each connection

is:
a) Clean
b) Firmly bolted
c) Crimped
d) Clamped
e) All test equipment removed.
Comments
Signatures / Date
Customer
Rolls-Royce
24
Completed Witnessed
Activity 80 - Verify operation of

Customer AC/DC Power Distribution
and Uninterrupted Power Supply
Reference Documents
GED00220838 - ECS/SIS/PCS UCO Outline
Schematic
GED00220841 - ECS/SIS/PCS UCP Panel Assembly
Arrangement
GED00210366 - Utility Consumption List
Customer AC/DC Power Distribution Drawings
Entronics Installation Manual E555-000L-0511 Vendor

literature Rolls-Royce Controls Installation Manual
Instructions Notes
1) Verify customer supplied power meets requirements
as specified in R-R Utilities Requirements and
specifications.
2) Battery system may require external load testing to
insure R-R requirements are meet.
Comments
Signatures / Date
Customer
Rolls-Royce
25
Completed Witnessed
Instructions
1) 1) Verify 120 VAC UPS power is available and
operates within R-R specifications.
2) 2) Verify 120 VAC commercial power is available and
operates within R-R specifications.
3) 3) Verify 24VDC Battery Back Up power is available
and operates within R-R specifications
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
26
Completed Witnessed
Activity 81 - Wire Check and Power-up

Package AC Power Lighting
Reference Documents
GED00221287 - General Arrangement
GED00221291 - Electrical Interface
GED00226679 - AIFH Electrical Installation
GED00226674 - AIFH Control Panel Layout
Customer AC power distribution drawings
Instruction Notes
Verify all circuits are properly isolated before energizing
power
Instructions
Verify resistance of power circuits prior to energizing.
Energize AC power lighting circuits for each of the following

devices:
Comments
Signatures / Date
Customer
Rolls-Royce
27
Completed Witnessed
1) GT Enclosure
2) GT Air Filter (AAF) Enclosure
3) SCR/CEMS Building
4) Generator
Verify proper operation of light fixtures and switches.

Return any safety devices removed during testing.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
28
Completed Witnessed

Package Emergency Lighting
Reference documents
Customer DC Power Distribution drawings

Instruction Notes
Verify all circuits are properly isolated before energizing
power
Instructions
Verify resistance of power circuits prior to energizing.
Energize DC Emergency power lighting circuits for each of
the following devices:
1) GT Enclosure Emergency Lighting
Verify proper operation of light fixtures.
Return any safety devices removed during testing.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
29
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
30
Completed Witnessed

Unit Control Panel
Reference Documents
GED00220838 - ECS/SIS/PCS UCP Outline

Schematic
Customer AC power distribution drawings

Instructions Notes
1) Verify all circuits are properly isolated before
energizing power. (UCP external circuits can be
isolated at TB knife switch.)
2) Check circuits prior to energizing for proper resistance
to ground.
3) Power up each circuit individually and verify proper
indication.
Comments
Signatures / Date
Customer
Rolls-Royce
31
Completed Witnessed
4) Disconnect all external communications cables until

circuits have been verified.
Instructions
Perform wire checks and power up the following groups of
circuits in the Unit Control Panel:
1) 120VAC power circuits (panel lighting circuits)
2) 24VDC power circuits
3) Programmable Logic Controllers
4) I/O Modules (Analog I/O, Digital I/O, Moog I/O, RVDT
Input, Vibration/Speed, etc)
5) Communications Modules
6) Control Circuits
7) HMI computer
8) UCP Cooling Fans
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
32
Completed Witnessed

GT Enclosure Panel
Reference Documents
Schematic
GED00194726 - Wiring Distributed I/O Interconnect

Instructions Notes
energizing power.
to ground.
indication.
Instructions
Comments
Signatures / Date
Customer
Rolls-Royce
33
Completed Witnessed

circuits in the each of the following Junction Box at GT
Enclosure:
A) GTI-4
2) I/O Modules
B) GTI-1
2) I/O Modules
C) GTI-2
2) I/O Modules
D) GTI-3
2) I/O Modules
DO NOT POWER UP QDM UNTIL LATER
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
34
Completed Witnessed

Generator Monitoring Panel
Reference Documents
Schematic
Arrangement

Instructions Notes
energizing power.
to ground.
indication.
Instructions
Comments
Signatures / Date
Customer
Rolls-Royce
35
Completed Witnessed

circuits in the each of the following Generator Monitoring
Panel circuits at Generator Enclosure:
2) I/O Modules
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
36
Completed Witnessed

GT Electric Starter
Reference Documents
Schematic
GED00220840 - Topology Diagram
Vendor Literature
Ultra Electric Start Handbook Doc #1003795
**Warning disconnect motor leads from drive output
terminals and before applying power**
Instructions Notes
energizing power.
to ground.
indication.
5) Verify proper input power taps on input transformer.
Comments
Signatures / Date
Customer
Rolls-Royce
37
Completed Witnessed
6) Configure communications for each device.

Instructions
circuits in the each of the following
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
38
Completed Witnessed

Fire and Gas System
Reference Documents
Schematic
GED00196976 - Fire and Gas Wiring
Vendor Literature
Fire System vendor documentation

Instructions Notes
energizing power.
to ground.
indication.
Comments
Signatures / Date
Customer
Rolls-Royce
39
Completed Witnessed

Instructions
1) Power up EQP and download software.
2) Power up device loops and verify communications on
EQP as devices are activated.
3) AC power for CO2 skid heater.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
40
Completed Witnessed
Activity 88 - Power-up Main Control

Room HMI (FT-210) and establish
communication
Reference Documents
GED00220843 - HMI Screen
Installation
1) Set up the computer, monitor, and printer in the
appropriate control locations.
Note: Note: Ensure that the equipment's voltage switch on
the back of the power supply is set to the appropriate site
voltage.
2) Plug the computer in and connect the Ethernet and
serial connections to the FT-210 network.
3) Ensure that the appropriate interface cables are used
as per the FT-210 User's manual. For more
information, refer to chapter "Engineering Standards,
Forms, and Drawings."
4) Turn on and boot the computer and initiate the HMI
program.
5) Verify all programs are operational.
6) Run scan disk on the hard drives to ensure that there
are no bad sectors on the hard drive.
Comments
Signatures / Date
Customer
Rolls-Royce
41
Completed Witnessed
7) Install printer cartridges in the printer (if supplied) and

print a test page.
8) Run the "Align Print Heads" task from the printer
properties.
9) Repeat this activity for all other HMI's supplied.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
42
Completed Witnessed
Activity 89 - Establish Control Net,

Device Net and Ethernet
Communications
Reference Documents
Schematic
Arrangement
GED00221292 - Auxiliary Electrical Equipment
GED00226679 - AIFH Electrical Installation
GED00226674 - AIFH Control Panel Layout
Vendor Documentation
Instructions Notes
Confirm communications cables connected.
Confirm configuration software is available and download.
Confirm ethernet communications networks (SCR
communications to VFD drives)
Comments
Signatures / Date
Customer
Rolls-Royce
43
Completed Witnessed
Confirm controlnet communications networks

Confirm devicenet communications networks (MCC
gateway)
Confirm modbus communications networks( GCPP)
Instructions
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
44
Completed Witnessed
Activity 90 - Motor Control Center

Functional Test (by others)
Reference Documents
Schematic
Arrangement
Customer Drawing:
Applicable Motor Control Center
**Warning dis-connect motor leads from contactor output

Instructions Notes
energizing power.
to ground.
Comments
Signatures / Date
Customer
Rolls-Royce
45
Completed Witnessed

indication.
Instructions
1) Verify MCC overload settings are in agreement to
motor nameplate data.
2) Verify E-stop command in manual and automatic
mode.
3) Verify local and remote start and stop for each device,
utilize HMI screen when possible.
4) Verify motor heaters are powered on when motor is
commanded off, verify proper current for each heater.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
46
Completed Witnessed
Activity 91 - Generator DC Lube Oil

Control Functional Test
Reference Documents
Schematic
Customer Drawing:
Applicable Motor Control Center
**Warning dis-connect motor leads from contactor output

Instructions Notes
energizing power.
to ground.
indication.
Instructions
Comments
Signatures / Date
Customer
Rolls-Royce
47
Completed Witnessed

1) Verify overload settings are in agreement to motor
nameplate data.
2) Verify E-stop command in manual and automatic
mode.
3) Verify remote start and stop for each device, utilize
HMI screen when possible.
4) Verify upon loss of power to PLC output command
pump operates.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
48
Section II Mechanical Pre-
commissioning
Activities
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Section I Introduction: Mechanical Pre-

commissioning Activities
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Completed Witnessed
Activity 92 - Check Customer

Connections for the A/C Generator Lube
Oil System
Reference Documents
GED00221295 - AC Generator Piping and Instrumentation
Diagram
GED00226496 - AC Generator Lube Oil System Diagram
Generator vendor literature
GEM0037 Pipe Cleaning
Mitten Vendor Manual and Drawings
Siemens Vendor Manual and Drawings
Instructions
1) Check that the customer connections (piping) have
been made in accordance with the Rolls-Royce
drawings.
2) Check that the customer interconnecting pipe work
has been cleaned per GEM0037.
3) Check that the customer interconnecting pipe work
has been fitted with suitable gaskets, studs, and
supports.
Note: The A/C Generator Skid piping and the Mitten Lube
Oil skid piping were cleaned in the factory and their flanges
Comments
Signatures / Date
Customer
Rolls-Royce
53
Completed Witnessed
were sealed. It is essential that great care be taken to

prevent contamination of the system. Before removing
piping and valves ensure that everything is clean to
prevent accidentally contaminating the system. Cover/
protect all open connections.
A/C Generator Skid Connections
M200B - Jacking Oil Supply to Generator
M201B - Jacking Oil Supply to Generator
M206B - Main Mechanical Pump Suction
M207B - Main Mechanical Pump Discharge
M208B - Lube Oil Supply
M209B - Lube Oil Return
A/C Generator Lube Oil Skid Connections
M200A - Jacking Oil Supply to Generator
M201A - Jacking Oil Supply to Generator
M206A - Main Mechanical Pump Suction
M207A - Main Mechanical Pump Discharge
M208A - Lube Oil Supply
M209A - Lube Oil Return
M210 - Blower Vent
M212 - Reservoir Drain
Comments
Signatures / Date
Customer
Rolls-Royce
54
Completed Witnessed
Activity 93 - Check Rolls-Royce

Connections for the Inlet Air System
Reference Documents
GED00207956 - Trent 60 WLE GT Fire & Gas System
GED00207950 - Trent 60 WLE Instrument Air &
Demineralized Water Supply System
GED00207959 - Trent 60 WLE Ventilation System Diagram
Retention Damper DP1 (703)
1) Check tubing connection (703) between GT Enclosure
roof and the AAF Fire Retention damper.
2) Check that all the pipe work /tubing has been fitted
with suitable supports.
3) Check that the interconnecting pipe work / tubing has
been cleaned per GEM0037.
Retention Damper DP2 (702)

1) Check tubing connection (702) between GT Enclosure
roof and the AAF Fire Retention damper.
Comments
Signatures / Date
Customer
Rolls-Royce
55
Completed Witnessed
GT Air Intake Pulse Clean (M303)

1) Check tubing connection (M303) between GT
Enclosure roof and the AAF Fire Retention damper.
Note: The Rolls-Royce Gas Turbine skid air systempiping

were cleaned in the factory and their flanges were sealed.
It is essential that great care be taken to prevent
contamination of the system. Before removing piping and
valves ensure that everything is clean to prevent
accidentally contaminating the system. Cover/protect all
open connections.
Comments
Signatures / Date
Customer
Rolls-Royce
56
Completed Witnessed
Activity 94 - Check the Correct

Installation of the Vent Fans
Reference documents
Note:
Check the vendor's installation and operating manuals for
the correct fan blade pitch and drive belt installation on the
gas turbine (GT) enclosure ventilation fans.
Comments
Signatures / Date
Customer
Rolls-Royce
57
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
58
Completed Witnessed

Connections for A/C Generator Lube Oil
Cooling System
Reference documents
GED00221295 - AC Generator Piping and Instrumentation
Diagram
Generator vendor literature
Mitten Vendor Manual and Drawings
Siemens Vendor Manual and Drawings
Instructions
drawings.
2) Check that the Customer interconnecting pipe work
supports.
Note: The A/C Generator Lube Oil skid cooler and piping
Comments
Signatures / Date
Customer
Rolls-Royce
59
Completed Witnessed

open connections.
A/C Generator Lube Oil Skid Connections
M204 - Cooler Glycol Outlet
M205 - Cooler Glycol Inlet
Comments
Signatures / Date
Customer
Rolls-Royce
60
Completed Witnessed

Connections for GT Cooling Water
System
Reference documents
GED00207863 - Trent 60 WLE Lube Oil System Diagram
Note: The Customer supplies cooling water for cooling the
GT lube oil and the P30 Air.
GT Skid Connections
M003 - Customer Cooling Water Supply
M004 - Customer Cooling Water Return
M613- P30 Coolant Supply
M614- P30 Coolant Return
drawings.
supports.
Comments
Signatures / Date
Customer
Rolls-Royce
61
Completed Witnessed
Note: The Rolls-Royce Gas Turbine skid coolers and piping

open connections.
Comments
Signatures / Date
Customer
Rolls-Royce
62
Completed Witnessed
Activity 97 - Gas Fuel Leak Test
Reference Documents
GED00207951 - Trent 60 WLE Fuel Gas System
GEM 0042 - Leak Test Procedure
GEM 0077 - Gas Fuel System Test Procedure For An
Industrial Trent Phase III Package - Factory and Field
GEM 0088 - Handling and Installing Flexible Hose
GEM 0123 - Application of High Temperature Pure Nickel
Anti-Sieze Compound
GEMF0042 - Package Leak Test Record
GTES 10157 - Fuel Acceptability Criteria for Trent 60 WLE
GTES 10540 - Trent 60 WLE D/F Production Acceptance
Test Schedule
Fittings
Primary pot top male 1.3125 - 12 UNJ 37 Flare, 8 off
Secondary pot top male 1.625 - 12 UNJ 37 Flare, 8 off
Safety Note: Compressed gas pressure testing involves
the hazard of released energy stored in the gas. This
procedure should be carried out in accordance the site
health and safety regulations and as a minimum Personal
Protective Equipment (PPE) should be worn, including eye
protection.
Testing
Comments
Signatures / Date
Customer
Rolls-Royce
63
Completed Witnessed
1) Follow the detailed procedures in GEM's 0042 and

0077.
2) Ensure that the instrument calibrations have been
completed.
3) Disconnect the primary and secondary pigtails from
the combustors.
4) The special blanking plugs should first be screwed
onto their corresponding interface on the combustor,
providing an anchor, then attach the pigtails to their
plugs. An approved anti-seize compound should first
be applied to the threads as defined in Rolls-Royce
Engineering Standard GEM 0123. For more
information, refer to "Engineering Standards, Forms,
and Drawings”.
Safety Note: Do not subject the flexible pigtails to undue
stress or bending. Maltreatment may result in a failure of
the pipe. The pigtails should be supported in an unstressed
state at all times.
5) It is recommended that seal tape is placed around
each flange to test for nitrogen leakage with a small
hole inserted in the tape at a convenient position to
apply the leak test fluid.
Note: Only industry approved leak detection fluids shall be
used.
Soap solutions and washing up liquids must not be used,
as they can cause corrosion. After leak testing, all joints
shall be wiped dry.
Comments
Signatures / Date
Customer
Rolls-Royce
64
Completed Witnessed
6) Position valves per the instructions. With the gas

system valves set to the test positions the test can be
started.
a) Gradually pressurise the system to two (2) barg.
b) Lock this pressure into the system by closing the test
isolation valve.
c) Monitor and trend of the test gas pressure in the
system, via the HMI (gas skid inlet pressure).
d) If the two (2) bar test is successful, open the isolation
valve and gradually increase the pressure to five (5)
barg, then in five (5) bar stages to the 40 barg final test
pressure.
e) All leaks must be rectified.
Note: There are no acceptance limits for leaks.
f) At 10, 20 and 30 barg, lock the pressure into the
system and monitor via the HMI.
g) The final test pressure shall be set at 40 barg. Lock the
pressure into the system and after it stabilises check
that it remains within 10 mbar for five (5) minutes.
h) At the end of the test, the test gas should be isolated
at the bottle.
i) The gas system vents should be opened via the HMI
(Human Machine Interface).
7) The test gas must be depressurised to a well
ventilated environment. It is essential to ensure that all
Comments
Signatures / Date
Customer
Rolls-Royce
65
Completed Witnessed
lines are vented and that no gas pressure is left in

dead spaces.
8) Restore all valves to their normal shutdown positions.
9) Restore all control interlocks to their normal shutdown
state.
10) Remove all test equipment.
Comments
Signatures / Date
Customer
Rolls-Royce
66
Completed Witnessed

Connections for All Drains
Reference Documents
GED00194680- Piping - LO Drain-Supply
GT Skid Connections
M024 - Water Injection Drain
M105 - GT Oil Reservoir Drain
M398 - Liquid Fuel Purge Air Drain
M505 - Liquid Fuel Drain
M607- ISI Drain
M611 - ISI Wet Compression Array/Intake Plenum Drain
M612 - Water Wash Drain
M615- P30 Drain
M632 - ISI Drain
M660A - Skid Drain
M660B - Skid Drain
M660C - Skid Drain
M660D - Skid Drain
M660E - Skid Drain
Comments
Signatures / Date
Customer
Rolls-Royce
67
Completed Witnessed
M660F - Skid Drain

M660G - Skid Drain
M660H - Skid Drain
M660I - Skid Drain
M660J - Skid Drain
M660K - Skid Drain
GT Air Filter House Connections
M636A - Filter House Duct Drain
M636B - Filter House Duct Drain
A/C Generator Connections
M212 - Oil Reservoir Drain
drawings.
supports.
Comments
Signatures / Date
Customer
Rolls-Royce
68
Completed Witnessed
Activity 99 - Check All Electric Pump

Rotations
Reference Documents
Piping and Instrumentation Diagram
Mitten Vendor manual and drawings
Caldwell Vendor manual and drawings
Motor Control Center vendor literature (by others)
Activity
The direction of rotation of all electric motors must be
verified.
Refer to the vendor's manuals and drawing to determine if
the
Driven equipment must be uncoupled, or the motor rotation
can be safely tested by the "bump" method.
Comments
Signatures / Date
Customer
Rolls-Royce
69
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
70
BAYONNE ENERGY CENTER - M.A371.01
Completed Witnessed
Activity 100 - Check All Fan Rotations
Reference Documents
Motor Control Center vendor literature (by others)
Mitten Vendor manual and drawings
Activity
The direction of rotation of all electric fans must be verified.
Refer to the vendor's manuals and drawing to check the
correct fan blade pitch and drive belt installation on the gas
turbine (GT) enclosure ventilation fans.
Note: Note: This activity must be done in conjunction with
the Rolls-Royce Control representative.
Gas Turbine Enclosure
Enclosure Fan #1
Enclosure Fan #2
Enclosure Fan #3
A/C generator Lube Oil Skid
Oil Reservoir blower fan
Comments
Signatures / Date
Customer
Rolls-Royce
71
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
72
Completed Witnessed
Activity 101 - Inspect, Clean and Fill the

A/C Generator Oil Reservoir
Reference Documents
GEM 0037 - Pipe Preparation and Cleaning
Generator vendor documentation
Note: The generator LO tank will be shipped as a complete
unit from the factory where a system flush will have been
carried out. Therefore, the system should be received in a
clean, ready to run condition. However there is a
requirement to carry out a precautionary tank inspection
and system flush after package installation at site.
Inspection and Filling
1) Remove the tank inspection covers and inspect the
tank for cleanliness according to Rolls-Royce
2) Use a portable wet/dry vacuum cleaner to remove any
foreign material from the reservoir interior as needed.
3) Clean reservoir with a cloth moistened with a cleaning
solvent.
4) Test wipe using a clean cloth. The cloth should remain
visibly clean, free from oil film, grime and grit. Repeat
Comments
Signatures / Date
Customer
Rolls-Royce
73
Completed Witnessed
cleaning and inspection until cloth remains visibly

clean.
Safety Note: Warning: If reservoir is opened for inspection
of the interior, assure that adequate ventilation is provided
and that necessary safety precautions are taken for
confined space.
5) Process connections to off-console components must
also be completed prior to commencing flushing (i.e.,
filters, demister and associated piping).
6) Assure that the isolation ball valves are closed on the
reservoir sample line and the drain line.
7) Open filter bowls to assure that elements are present.
8) Remove filter elements and inspect filter housing
internally for cleanliness.
9) Clean with cloth moist with cleaning solvent. Cloth
should remain visibly clean, free from oil film, grime
and grit.
10) Re-install filter elements.
11) Inspect reservoir drains for cleanliness. Clean with
cloth moistened with cleaning solvent as required.
Note: The oil must meet the Seimens cleanliness
requirement.
12) Fill the A/C Oil reservoir with Siemens approved oil.
Ensure that the correct fill points are used and that
filters are installed.
Comments
Signatures / Date
Customer
Rolls-Royce
74
Completed Witnessed
Note: It is essential that great care be taken to prevent

contamination of the system after the completion of
Flushing.
Before removing any connections or protective covers /
caps, ensure that everything is clean to prevent
accidentally contaminating the system.
Comments
Signatures / Date
Customer
Rolls-Royce
75
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
76
Completed Witnessed
Activity 102 - Inspect, Clean and Fill The

Gas Turbine Oil Reservoir
Reference Documents
GEM 0267 - Flushing Trent 60 Electric Gas Turbine Oil
System
Note: The Gas Turbine Oil System is combined of GT Lube
oil, Hydraulic Control oil, and electric start cooling oil.
This oil system shall be shipped to site fully installed on the
GT baseplate and factory flushed. However there is a
and system flush after package installation at site.
Inspection and Filling
1) Remove the tank inspection covers and inspect the
tank for cleanliness according to Rolls-Royce
2) Use a portable wet/dry vacuum cleaner to remove any
foreign material from the reservoir interior as needed.
3) Clean reservoir with a cloth moistened with a cleaning
solvent.
4) Test wipe using a clean cloth. The cloth should remain
visibly clean, free from oil film, grime and grit. Repeat
Comments
Signatures / Date
Customer
Rolls-Royce
77
Completed Witnessed
cleaning and inspection until cloth remains visibly

clean.
Safety Note: Warning: If reservoir is opened for inspection
of the interior, assure that adequate ventilation is provided
and that necessary safety precautions are taken for
confined space.
5) Process connections to off-console components must
also be completed prior to commencing flushing (i.e.
filters, demister and associated piping).
6) Assure that the isolation ball valves are closed on the
reservoir sample line and the drain line.
7) Open filter bowls to assure that elements are present.
8) Remove filter elements and inspect filter housing
internally for cleanliness.
9) Clean with cloth moist with cleaning solvent. Cloth
should remain visibly clean, free from oil film, grime
and grit.
10) Re-install filter elements.
11) Inspect reservoir drains for cleanliness. Clean with
cloth moistened with cleaning solvent as required.
Note: The oil must meet the Rolls-Royce cleanliness
requirement given in the Trent Interface Control Document
GTES 10245.
This is 16/14/12 for ISO 4406 or Class 6 for NAS 1638.
12) Fill the combined gas turbine (GT) Oil Reservoir with
the approved oil. Only those oils specified in GTES
Comments
Signatures / Date
Customer
Rolls-Royce
78
Completed Witnessed
10245 are to be used. Ensure that the correct fill

points are used and that 3 micron filters are installed.
flushing. Before removing any connections or protective
covers / caps, ensure that everything is clean to prevent
Safety Note: 1) Synthetic oil contains additives which after
prolonged skin contact can be toxic through absorption.
Protective clothing, gloves and eye protection should be
worn as a minimum.
Comments
Signatures / Date
Customer
Rolls-Royce
79
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
80
Completed Witnessed
Activity 103 - Blow Down Gas Fuel

System
Reference documents
GED00207946 - Trent 60 WLE P30 Purge Air System
Diagram
GED00207951 - Trent 60 WLE Gas Fuel Metering System
Diagram
GED00207950 - Trent 60 Instrument Air & Demineralized
Water Supply System Diagram
GTES 10157 - Fuels acceptability criteria for Industrial
Trent WLE
Note: This Rolls-Royce gas fuel system shall be shipped to
site fully installed on the GT baseplate. The system was
cleaned in the factory and the flanges were sealed. It is
essential that great care be taken to prevent contamination
of the system. Before removing piping and valves ensure
that everything is clean to prevent accidentally
contaminating the system. Cover/protect all open
connections.
Blow Down
1) Using high volume, high pressure air, blow down the
customers gas fuel piping system up to the Gas
Turbine skid (Customer Connection M410).
2) Use suitable targets to insure the piping is clean.
Comments
Signatures / Date
Customer
Rolls-Royce
81
Completed Witnessed
3) After verification that the customers gas fuel piping is

clean up to the Rolls-Royce skid (M410) connect the
customers piping.
4) If required install a temporary screen at connection
M410.
Comments
Signatures / Date
Customer
Rolls-Royce
82
Completed Witnessed
Activity 104 - Clean and Inspect the

Combined Gas Turbine Air Intake
System
Reference Documents
GEM 0034 - Lockwiring Procedure
GEM 0043 - Application of RTV-106 Adhesive Sealant
AAF Air Intake vendor documentation
Note: This should be inspected and signed off by two (2)
Rolls-Royce representatives.
Air intake system inspection (Upper access door)
1) Inspect the interior of the air filter house, beginning at
the downstream side of the filters. Inspect for debris
and foreign material.
Perform a "white glove" inspection. Vacuum and hand
clean if necessary.
2) Pay particular attention to the combustion inlet inlet
silencer section. Check between each silencer baffle
for debris and foreign material.
3) Check that all internal mechanical fasteners and
devices have been positively locked, either wire locked
or tack welded.
Comments
Signatures / Date
Customer
Rolls-Royce
83
Completed Witnessed
4) Check that all seals in the system have been fitted and
that were necessary mastic has been used to maintain
an airtight seal.
5) Check that the fire and non-return dampers operate
correctly and give the required indications.
Air intake system inspection (filter access door)
1) Inspect the interior of the air filter house at the
upstream side of the filters. Inspect for debris and
foreign material.
Perform a "white glove" inspection. Vacuum and hand
clean if necessary.
2) Ensure that all filters are fitted according to the
manufacturer's installation and operation procedures.
an airtight seal.
4) Check that all door switches are giving the correct
indications.
5) Check that the filter house lights are operational.
6) Check that all intake drains are free from debris.
7) After inspection lock all the access doors/ hatches to
prevent subsequent entry. Ensure that warning signs
are posted that entry is prohibited.
8) Put warning notices on the doors and hatches warning
that entry is prohibited.
Comments
Signatures / Date
Customer
Rolls-Royce
84
Completed Witnessed
9) Check the operation of the Pulse air Filter Cleaning

System.
Safety Note: Before operating the pulse air system ensure
that the intake walkways access ladders and immediate
area around the filter house has been cleared of all but
essential personnel.
Comments
Signatures / Date
Customer
Rolls-Royce
85
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
86
Completed Witnessed
Activity 105 - Clean and Inspect the Gas

Turbine Air Inlet Plenum
Reference Documents
GED00207857 - Trent 60 WLE Combustion Air Diagram
GEM 0034 - Lockwiring Procedure
GEM 0043 - Application of RTV-106 Adhesive Sealant
AAF vendor manual and drawings.
Note: This activity should be performed and signed off by
two (2) Rolls-Royce representatives.
Inspection
1) Inspect the interior of the gas turbine inlet air plenum
for debris and foreign object. Perform a "white glove"
inspection.
an airtight seal.
3) Check that the quick release flexible joint is secured
and locked into position.
Check for any air gaps on the joint sealing areas.
4) Check that all intake drains are free from debris.
5) After the inspections lock all the access doors/
hatches to prevent subsequent entry. Ensure that
warning signs are posted that entry is prohibited.
Comments
Signatures / Date
Customer
Rolls-Royce
87
Completed Witnessed
6) Put warning notices on the doors and hatches warning

that entry is prohibited.
Comments
Signatures / Date
Customer
Rolls-Royce
88
Completed Witnessed
Activity 106 - Inspect and Flush the

Package Gas Turbine Air Service
System
Reference Documents
GED00221289 - Shipping Outline
GED00207857 - Trent 60 WLE Combustion Air System
Diagram
GED00207946 - Trent 60 WLE P30 Purge Air System
Diagram
GEM 0032 - Tightening of Threaded Fasteners and
Torquing Sequence for Flanged Joints and Rotabolt
Applications
GTES 10155 - Gas Fuel Acceptability Criteria for Industrial
Trent 60
Comments
Signatures / Date
Customer
Rolls-Royce
89
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
90
Completed Witnessed
Activity 107 - Flush the Gas Turbine Oil

System
Reference Documents
GED00194684 - Flushing Loop
GED00207863 - Trent 60 WLE Gas Turbine Lube Oil
System Diagram
System
Note: The gas turbine oil system is combined of GT lube
oil, hydraulic control oil, and electric start cooling oil.
The systems will be flushed in a two (2) step procedure per
Rolls-Royce Engineering Standard GEM 0267.
This oil system shall be shipped to site fully installed on the
GT baseplate and factory flushed. However there is a
and system flush after package installation at site. The
system was inspected and filled with clean and correct oil
in a prior activity.
Flushing. Before removing any connections or protective
Flushing Hydraulic Oil and Electric Start motor
Cooling oil
Comments
Signatures / Date
Customer
Rolls-Royce
91
Completed Witnessed
1) Install the Rolls-Royce supplied Flushing jumpers.

2) Follow the procedure in Rolls-Royce Engineering
Standard GEM 0267.
requirement list In the Rolls-Royce Engineering Standard
GEM 0267. This is 16/14/12 for ISO 4406 or Class 6 for
NAS 1638.
Flushing Lubricating Oil and Electric Start motor
Cooling oil
1) Install the Rolls-Royce supplied flushing jumpers.
2) It is essential to ensure good engineering practices are
maintained to prevent contamination of the system.
3) Follow the procedure in Rolls-Royce Engineering
Standard GEM 0267.
requirement list in the Rolls-Royce Engineering Standard
GEM 0267. This is 16/14/12 for ISO 4406 or Class 6 for
NAS 1638.
Safety Note: 1) Synthetic oil contains additives which after
prolonged skin contact can be toxic through absorption.
protective clothing, gloves and eye protection should be
worn as a minimum.
Comments
Signatures / Date
Customer
Rolls-Royce
92
Completed Witnessed
Activity 108 - Flush A/C Generator Lube

Oil System
Reference documents
GEM 0038 - Flushing Main Lubricating Oil Systems -
Factory and Field
Siemens Vendor Manual
Note: The A/C generator Lube Oil skid will be shipped as a
complete unit from the factory where a system flush will
have been carried out. Therefore, the system should be
received in a clean, ready to run condition.
However the interconnect piping between the A/C
generator skid and the lube oil skid was field fabricated and
installed. This flushing activity is required to insure the
complete oil system is clean.
Flushing Lube Oil
1) Fabricate and install flushing jumpers as required.
3) Follow the procedure in the Siemens Vendor Manaul.
requirement.
Comments
Signatures / Date
Customer
Rolls-Royce
93
Completed Witnessed
Flushing Jacking oil

1) Fabricate and install flushing jumpers as required.
3) Follow the procedure in the Siemens Vendor Manaul.
requirement.
Flushing.
Comments
Signatures / Date
Customer
Rolls-Royce
94
Completed Witnessed
Activity 109 - Flush the Gas Turbine

Cooling Water System
Reference Documents
System Diagram
GED00221287 - Trent 60 WLE General Arrangement
Note: The gas turbine cooling water system will be shipped
as a complete unit from the factory where a system flush
will have been carried out. Therefore, the cooling water
system should be received in a clean, ready to run
condition. This activity is to insure the customers water
cooling system and site fabricated piping is clean and does
not contaminate the Rolls-Royce supplied coolers.
The gas turbine water cooling system consist of two (2)
cooler. The lube oil cooler (HE0700) and the air cooler
(HE0101).
Flushing Gas Turbine Water coolers
1) Fabricate and install flushing jumpers as required. This
is normally a jumper connection (either a hose or pipe)
between the water cooling inlet connection (M003) and
the water cooling outlet connection (M004).
2) Install 100 mesh screen with 40 mesh as a back up at
jumper hose connection (M205).
Comments
Signatures / Date
Customer
Rolls-Royce
95
Completed Witnessed

3) Check that the customers water cooling system valves
and regulators are properly position for flushing.
4) Start the cooling water system, but only operate it for 5
minutes. Inspect the flushing screen. Note the amount
of foreign matter/debris and determine the time period
for the next flushing cycle. If the screens are fairly
clean then increase the flushing cycle time. If the
screen are covered with debris then only flush for
another 5 minutes before inspecting. The amount of
debris Determines the flushing cycle time.
Note: If after several flushing cycles the screens are still
not clean this indicates the customers cooling water
system is contaminated. Locate the source (piping and/or
the water) of the contamination and take corrective action.
5) Continue flushing until the system can be operated for
two hours and no debris is collected on any of the
flushing screens. The system is considered clean
when this criteria is met.
WARNING:
Do not connect a contaminated cooling water system to the
unit coolers! Contamination will result in clogged/damaged
coolers!
Comments
Signatures / Date
Customer
Rolls-Royce
96
Completed Witnessed
Activity 110 - Flush A/C Generator Lube

Oil Cooling Water System
Reference documents
Factory and Field
Note: The A/C generator LO Skid will be shipped as a
complete unit from the factory where a system flush will
have been carried out. Therefore, the system should be
received in a clean, ready to run condition. This activity is
to insure the customers water cooling system and site
fabricated piping is clean and does not contaminate the
Rolls-Royce supplied LO skid cooler.
Flushing
1) Fabricate and install flushing jumpers as required. This
is normally a jumper connection (either a hose or pipe)
between the water cooling inlet connection (M205) and
the water cooling outlet connection (M204).
2) Install 100 mesh screen with 40 mesh as a back up at
jumper hose connection (M205).
Comments
Signatures / Date
Customer
Rolls-Royce
99
Completed Witnessed

3) Check that the customers water cooling system valves
and regulators are properly position for flushing.
4) Start the cooling water system, but only operate it for 5
minutes. Inspect the flushing screen.
Note the amount of foreign matter/debris and determine
the time period for the next flushing cycle. If the screens
are fairly clean then increase the flushing cycle time. If the
screen are covered with debris then only flush for another 5
minutes before inspecting. The amount of debris
determines the flushing cycle time.
Note: If after several flushing cycles the screens are still
not clean this indicates the customers cooling water
system is contaminated. Locate the source (piping and/or
the water) of the contamination and take corrective action.
5) Continue flushing until the system can be operated for
two hours and no debris is collected on any of the
flushing screens. The system is considered clean
when this criteria is met.
WARNING:
Do not connect a contaminated cooling Water System to
the unit coolers! Contamination will result in clogged/
damaged coolers!
Comments
Signatures / Date
Customer
Rolls-Royce
100
Completed Witnessed
Activity 111 - Blow Down and Leak Test

CO2 System
Reference Documents
GED00207956 - Fire and Gas System Diagram
Det-Tronics Vender Information
Note: The maximum number of turn fittings or bends
between connections M700 and M701 is eight (8) elbows
with a maximum distance of 10 meters of 1.50" OD SS
tubing, minimum 0.121: wall thickness.
Blow Down
1) Using high volume, high pressure air, blow down the
customers piping/tubing between M700 and M701.
2) Use suitable targets to insure the piping is clean.
3) After verification that the customers piping is clean up
connect reconnect the piping/tubing.
Leak Check
1) Using suitable plugs/cap blind off each CO2 nozzle.
Comments
Signatures / Date
Customer
Rolls-Royce
101
Completed Witnessed
2) Connect a pressurized nitrogen source at connection

M701 and pressurize the CO2 system.
3) After verification that no leaks exist restore the system.
Note: The Rolls-Royce Gas Turbine skid and the CO2
cabinet skid piping/tubing were cleaned in the factory and
their flanges were sealed. It is essential that great care be
taken to prevent contamination of the system. Before
removing piping and valves ensure that everything is clean
to prevent accidentally contaminating the system. Cover/
protect all open connections.
Comments
Signatures / Date
Customer
Rolls-Royce
102
Completed Witnessed
Activity 139 - Restore Gas Turbine Lube

Oil System
Reference Documents
GED00219251 - Lube Oil Console - Gas Turbine
GED00194684 - Flushing Loop
GED00207863 - Trent 60 WLE Oil System
System
Note: The Gas Turbine Oil System is combined of GT Lube
oil, Hydraulic Control oil, and electric start cooling oil. The
systems was flushed in a two (2) step procedure per Rolls-
Royce Engineering Standard GEM 0267.
Restoring
1) Remove the flushing jumpers. When removed the
Flushing jumpers associated equipment they must be
protected and put in a suitable storage container.
2) Connect all the oil system hoses and piping back to
their original position.
3) Replace all filter elements if required.
4) Top off the GG Oil reservoir as required.
5) Position all valve to their normal position.
Flushing.
Comments
Signatures / Date
Customer
Rolls-Royce
103
Completed Witnessed
Note: Before removing any connections or protective

Safety Note: Safety Note: Synthetic Oil Contains Addi-
tives Which After Prolonged Skin Contact Can Be
Toxic Through Absorption. Protective Clothing, Gloves
And Eye Protection Should Be Worn As A Minimum.
Comments
Signatures / Date
Customer
Rolls-Royce
104
Completed Witnessed
Activity 140 - Restore Gas Turbine Lube

Oil Cooling Water system
Reference Documents
System Diagram
GED00221287 - Trent 60 WLE General Arrangement
The Gas Turbine cooling system was flushed in a prior
activity. This activity is to Restore the customers cooling
water system back to its original condition.
Restoring
1) Remove the cooling water jumpers and screens at the
customer connections (M003) and (M004).
When removed the Flushing Jumpers and associated
equipment they must be protected and put in a suitable
storage container for future use.
Flushing.
Note: Before removing any connections or protective
Comments
Signatures / Date
Customer
Rolls-Royce
105
Completed Witnessed
2) Connect the customers cooling water piping up to the

gas turbine skid water connections (M003) and
(M004).
3) Check that the pipe work has been fitted with suitable
gaskets, studs, and supports.
5) Perform a leak check of the system piping.
Comments
Signatures / Date
Customer
Rolls-Royce
106
Completed Witnessed
Activity 141 - Restore A/C Generator

Lube Oil System
Reference documents
Factory and Field
The A/C Generator Lube oil system was flushed in a prior
activity. This activity is to Restore the lube oil and jacking
oil systems back to their original condition.
Restore Lube Oil
flushing jumpers and associated equipment they must
be protected and put in a suitable storage container for
future use.
4) Top off the Lube oil reservoir required.
Restore Jacking oil
Comments
Signatures / Date
Customer
Rolls-Royce
107
Completed Witnessed

Flushing Jumpers and associated equipment they
must be protected and put in a suitable storage
container for future use.
Flushing.
Comments
Signatures / Date
Customer
Rolls-Royce
108
Completed Witnessed
Activity 142 - Restore A/C Generator

Lube Oil Water Cooling System
Reference documents
Factory and Field
The A/C Generator Lube oil water cooling system was
flushed in a prior activity. This activity is to Restore the
customers cooling water system back to its original
condition.
Restoring
1) Remove the cooling water jumpers and screens at the
customer connections (M205) and (M204).
When removed the Flushing Jumpers and associated
equipment they must be protected and put in a suitable
storage container for future use.
Note: It Is Essential To Ensure Good Engineering
Practices Are Maintained To Prevent Contamination Of The
System.
Comments
Signatures / Date
Customer
Rolls-Royce
109
Completed Witnessed
2) Connect the customers cooling water piping up to the

A/C generator lube oil skid connections (M205) and
(M204).
3) Check that the pipe work has been fitted with suitable
gaskets, studs, and supports.
5) Perform a leak check of the system piping.
Comments
Signatures / Date
Customer
Rolls-Royce
110
Chapter 3 Commissioning
Activities
111
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Section I Controls / Electrical
Commissioning
Activities
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Section II Introduction: Controls/Electrical

Pre-commissioning Activities
secutive order. All Controls/Electrical Pre-commissioning Activities must be completed before proceeding to the
commissioning activities covered in Chapter 3.
115
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Completed Witnessed
Activity 143 - Instrumentation

Calibration and Loop Checks
Reference Documents
Commissioning Loop Check / Instrument Data Sheets
GED00220843 - HMI Screen
Schematic
Instructions
Please refer to Volume 3 - Loop Check Sheets for the
commissioning loop checks and instrument data sheets.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
117
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
118
Completed Witnessed
Activity 144 - Generator Protection

Relay Calibration and Secondary
Current Injection Test
Reference Documents
GED00220842 - Alarm Trip Matrix
Arrangement
GED00227922 - High Voltage Single Line Diagram
GED00230718 - AC Generator Outline Drawing
Customer Site Protective Relay Coordination Study
Customer Single Line Diagram
Instructions Notes
1) Protective Relay Test Set will be required for test
2) Serial Communications Map verification will be
completed during tests
3) Secondary current injection test should be carried out
during this testing phase.
Instructions
1) Protective Relay functional tests of all alarms and
shutdowns
2) Serial Communications Map verified at HMI during
relay test
Comments
Signatures / Date
Customer
Rolls-Royce
119
Completed Witnessed
3) Power Transducers verified at HMI/UCP using

protective relay test set.
4) Secondary Current Injection tests
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
120
Completed Witnessed
Activity 145 - Engine Geometry

Calibration
Reference Documents
Schematic
GTER 11863 - Trent ICS - Variable Geometry Calibration
Procedure
GTER 12000 - Setup and Calibration Guidance
MOOG G122-824-002 PI ServoAmplifiers
SCDR511-1 Signal Conditioners
Instructions
Please refer to GTER 12000 for the calibration procedure
Perform calibration on the following:
1)LP BOV LPBOV
2)LP VIGV VIGV
3)IP VSV IPVSV
4)IP Thrust Piston IPTP
5)LP Thrust Piston LPTP
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
121
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
122
Completed Witnessed
Activity 146 - Oil Quantitative Debris

Monitoring System Test and Calibration
Procedures
Reference Documents
GED00207863 - Engine Lube/Hydraulic Control Oil Piping
and Instrumentation Diagram
Schematic
Schematic
GER 0018 - Wiring System Engineering and Installation
Vickers vendor documentation
Instructions
Please refer to the Eaton/Vickers vendor documentation for
further information.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
123
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
124
Completed Witnessed
Activity 147 - Gas Turbine Gas Fuel

Valve Calibration
Reference documents
Schematic
Instructions
Reference vendor document, Moog DS2000XP Analog
FMV
Driver - Valve Travel Calibration Sequence in performing
this activity.
1) Verify proper configuration and operation of Gas Fuel
Valve Calibration
2) Verify proper serial numbers utilized is ECS software
Comments
Signatures / Date
Customer
Rolls-Royce
125
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
126
Completed Witnessed
Activity 148 - Gas Detector Calibration

and Testing
Reference Documents
GED00239644 - Fire & Gas Cause & Effect Drawing
GEM 0263 - Test Procedure - Gas Turbine Package Fire
Protection Site Dump Testing
Instructions:
1) Check Calibration of Gas Detectors as per Vendor
Documentation
2) Calibrate if required
3) Verify proper control response during calibration
check.
Comments
Signatures / Date
Customer
Rolls-Royce
127
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
128
Completed Witnessed
Activity 149 - Multi-Spectrum Flame

Detector Testing
Reference Documents
GED00239644- Fire & Gas Cause & Effect Drawing
Instruction Notes
Note: 1) Devices must be disconnected prior to performing
detection system tests to prevent unwanted actuation,
alarm, and extinguishing.
Note: 2) Before starting the testing, check and clean all of
the viewing windows on the detectors.
Instructions
Fire Alarm Test
1) Disable any fire extinguishing equipment that is
connected to the system.
2) Apply input power to the system. Allow a one (1)
second power-up delay.
3) Verify that all detectors are properly aimed at the area
to be protected.
Comments
Signatures / Date
Customer
Rolls-Royce
129
Completed Witnessed
4) Check each flame detector with actual flame.

5) Enable the fire extinguishing equipment when the test
is complete (if applicable).
Comments
Signatures / Date
Customer
Rolls-Royce
130
Completed Witnessed
Activity 150 - Functional Testing of

Horns, Strobes, and Release Devices
Reference Documents
GED00239644 - Fire & Gas Cause & Effect Drawing
Instruction Notes
1) To prevent unwanted actuation or alarm, extinguishing
devices must be disconnected prior to performing
detection system tests.
2) The fire alarm push buttons next to each entry door
must be tested as well as any manual pull box
mechanisms within the CO2 skids. This procedure
must be repeated for each manual fire station.
3) Each of the enclosures has been supplied with a
strobe indicating a fire system discharge. The GT
enclosure is also supplied with two (2) external red
strobes and a pre-release sounder.
4) In the event that a discharge squib is used instead of a
24VDC-release solenoid, the squib must be
disconnected in a statically safe manner and a resistor
Comments
Signatures / Date
Customer
Rolls-Royce
131
Completed Witnessed
wired in it place. Discharge verification can be verified

with a multi meter put across the resistor.
Note: Refer to the manufacturer's information for procedure
and resistor sizing.
5) Fire system alarms are often tied to the customers fire
panel. Consult with the customers site management
and coordinate this procedure to verify any customer
interface signals.
Instructions
Fire Alarm Test
1) Ensure that the fire system is operational and all of the
alarms are reset.
2) Ensure all personnel vacate the GT and generator
enclosures.
3) Ensure that all enclosure doors are closed.
4) Ensure that the discharge heads for the CO2 bottles
have been removed, and that there is no possibility of
discharging the system.
5) Activate one (1) manual discharge button.
6) Verify the pre-discharge sounder operates.
7) Verify that the strobes for the associated enclosure
activate.
8) Verify that the main discharge heads activate.
9) Verify that the secondary discharge heads activate.
Comments
Signatures / Date
Customer
Rolls-Royce
132
Completed Witnessed
10) Verify the fire control panel displays an active fire

condition.
11) Verify the HMIs display an active fire condition alarm
and GT shutdown.
12) Reset all alarms and fire discharge heads.
13) Repeat the above procedure for each manual fire
station.
14) If supplied, repeat procedure for any installed
customer remote fire stations
Illegal Enclosure Entry Alarm Testing
alarms are reset.
2) Ensure all personnel vacate the GT and Generator
enclosures.
3) Ensure that all enclosure doors are closed.
5) Open an enclosure door.
6) Verify that the sounder horn operates.
7) Verify that the fire strobes for the associated enclosure
activate.
8) Verify that the fire system displays "Illegal Enclosure
Entry".
Comments
Signatures / Date
Customer
Rolls-Royce
133
Completed Witnessed
9) Verify that the HMIs display an "Illegal Enclosure

Entry" alarm.
10) Close the enclosure door (that was opened in Step 5).
11) Reset all alarms.
12) Repeat the test for each enclosure access point/door.
Fire System Isolation Test
alarms are reset.
2) Ensure all personnel vacate the GT and Generator
enclosures.
4) Activate one (1) manual discharge button.
5) Verify the pre-discharge sounder operates.
6) Verify that the strobes for the associated enclosure
activate.
7) Verify that the main discharge heads do not activate.
8) Verify that the secondary discharge heads do not
activate.
9) Verify the fire control panel displays an active fire
condition.
10) Verify the HMIs display an active fire alarm condition
and GT shutdown.
Comments
Signatures / Date
Customer
Rolls-Royce
134
Completed Witnessed
11) Reset all alarms and fire discharge heads.

12) Return the fire system to its original status before
testing.
Problems and Notes
Comments
Signatures / Date
Customer
Rolls-Royce
135
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
136
Completed Witnessed
Activity 151 - Ignition Testing
Reference Documents
Schematic
GED00207861 - Engine Ignition and Instrumentation
Diagram
GED00200059 - Dist I/O Wiring
Instruction Note
Safety Note: Safety Note: The Unison Ignition box
should be securely closed to prevent any hazardous
incident from arising. The local area around the GT
enclosure should be appropriately cordoned off and
sign posted to indicate a hazardous test in progress.
One person in the gas turbine enclosure should verify
that igniters "Fire". Verify there is a safe condition to
test the ignition system.
Igniter System Operational Checks
1) Energize Ignition output command using forcing
functions with FT310 verify both ignitors are firing at
the proper repetition rate.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
137
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
138
Completed Witnessed
Activity 152 - Test and Set Panel Heaters
Reference Documents
GED00160539 - Generator Monitoring Panel
Schematic
Procedure
1) Verify that installation and loop check activities have
been completed for all panels and systems. This
information can be found in Volume III - Loop Check
Sheets.
2) Verify all heaters are properly in service and
operational.
Comments
Signatures / Date
Customer
Rolls-Royce
139
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
140
Section II Mechanical
Commissioning
Activities
141
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Section I Introduction: Mechanical

Commissioning Activities
143
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Completed Witnessed
Activity 154 - Generator Direct Air

Cooling DAC Testing
Reference Documents
GED00221295 - AC Generator Instrumentation System
Diagram
Siemens TurboGenerator Operations and Maintenance
Manual
Instruction Notes
Instruction
Verify proper operation of Generator Direct Air Cooling
System
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
145
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
146
Completed Witnessed
Activity 155 - GT (AAF) Pulse Air

Cleaning System Test
Reference Documents
GED00207857 - Combustion Air System Diagram
AAF Operations and Maintenance Manual
Instruction Notes
Instruction
Verify proper operation of Pulse Air Filter Cleaning System
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
147
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
148
Completed Witnessed
Activity 156 - GT Control Oil System

Function Test
Reference Documents
Schematic
GED00207863 - Gas Turbine Lube Oil System Diagram
Instructions
Verify operation as per system piping and instrumentation
diagram.
Monitor pressures during the operation, and ensure the
pump is making the appropriate pressure and flow.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
149
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
150
Completed Witnessed
Activity 157 - GT Electric Starter Motor

Cooling System Function Test
Reference Documents
Schematic
GED00207861 - Engine Iggition & Instrumentation
Diagram
Instruction Notes
Instructions
diagram.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
151
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
152
Completed Witnessed
Activity 158 - Generator Lube Oil Testing
Reference Documents
GED00226496 - AC Gen Lube Oil System Diagram
Instruction Notes
Instructions
diagram.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
153
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
154
Completed Witnessed
Activity 159 - Generator DC Lube Oil

Pump Testing
Reference Documents
GED002264961 - AC Gen Lube Oil Sys Diagram
Instruction Notes
Instructions
1) Check the motor overloads on the DC lube oil (LO)
Pump. Ensure they are set to maximum, or bypassed.
In the event of a failure the pump should be the
sacrificial portion of the LO system, protecting the
generator bearings as long as possible.
2) Check the DC lube oil pump fuses. The fuses should
check ok with a digital multimeter and should be a
minimum of 20 times full load pump current, or
bypassed completely.
3) Run the DC LO pump for a minimum of 24 hours to
prove pump reliability.
4) Monitor pressures during the operation, and ensure
the pump is making the appropriate pressure and flow.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
155
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
156
Completed Witnessed
Activity 160 - Compressor Water Wash
Reference Documents
GED00207955 - Cleaning System diagram
Instruction Notes
Instructions
diagram.
Monitor pressures during the testing of the water wash
skid, ensure the proper operation of solenoid valves.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
157
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
158
Completed Witnessed
Activity 161 - Emergency Shutdown

Checks
Reference Documents
Schematic
Procedure
Ensure power drops from all devices.
Comments
Signatures / Date
Customer
Rolls-Royce
159
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
160
Completed Witnessed
Activity 162 - Start-Up Sequence Checks
Reference Documents
Schematic
GED00220845 - Unit Control Panel Logic Flow Diagram
Instruction Notes
Instructions
Verify sequence completion with starter system disabled.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
161
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
162
Completed Witnessed
Activity 163 - CO2 Dump Test
Reference Documents
Vendor literature
Instructions
The performing of a CO2 dump test shall be the
responsibility of the customer, if required. They shall
provide a procedure that complies with their insurance
companies requirements. If a test is carried out then a copy
of the procedure is to be added to this manual along with
the following sign off.
Sign _____________Company_____________
DateDate_____________
Sign _____________Company_____________
DateDate_____________
Sign _____________Company_____________
DateDate_____________
Comments
Signatures / Date
Customer
Rolls-Royce
163
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
164
Completed Witnessed
Activity 164 - Engine Crank Test
Reference Documents
Schematic
Ultra Electric Starter Handbook 1003795
Instruction Notes
Instructions
Verify crank sequence.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
165
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
166
Completed Witnessed
Activity 165 - Gas Fuel Gas Analysis
Reference Documents
GTES 10157 - Fuel Acceptability Criteria for Trent 60 WLE
GTES 10540 - Trent 60 WLE D/F Production Acceptance
Test Schedule
Instruction Notes
Note: Note: It is the customer's responsibility to ensure that
the site installed gas supply meets the requirements
defined in the Rolls-Royce documents listed above.
Instructions
1) It is the customer's responsibility to ensure that a gas
analysis be performed prior to the initial start-up of the
engine.
2) This analysis should be confirmed by a Rolls-Royce
representative that the gas constitutants meet the
requirements.
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
167
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
168
Completed Witnessed
Activity 166 - Prior to First Fire (starting

unit for first time)
Reference Documents
GER 0018 - PMP modular wiring system engineering and
installation specifications
Procedure
Prior to starting any Rolls-Royce equipment for the first
time; the following checklist must be approved by the Rolls-
Royce Installation and Commissioning Manager (ICM) or
the Installation and Commissioning Services (ICS)Director.
Safety Note: Safety Note: If there are any jumpers or
bypasses in place, there is a risk of fire and/or equip-
ment damage. Therefore, any jumpers or bypasses
must be removed.
1) Inspect the gas turbine (GT), generally for cleanliness
and ensure that the unit is securely tightened on its
mountings with the air intake fitted securely.
2) Check the combustion air intake system for
abandoned tools and debris.
3) Check that the air filter house, from the downstream
side of the filters, has been thoroughly cleaned to
remove all traces of dirt.
4) Check the GT components, pipes and electrical
connections, especially those on the battery plate, for
Comments
Signatures / Date
Customer
Rolls-Royce
169
Completed Witnessed
security of attachment, evidence of "chafing", and

correct assembly.
5) Ensure that the oil levels are correct and that approved
lubricants only are used.
6) Ensure that the gas detection system is fully
operational and correctly calibrated.
Note: Some gas detectors require up to two hours to
stabilize prior to calibration, if they have been deenergized.
If in any doubt about calibration procedures or times,
contact the manufacturers of the detectors.
7) Ensure that the fire detection and extinguishing
system are also fully operational and correctly
calibrated.
8) Ensure that the fire dampers are also fully operational.
9) Ensure that all GT related auxiliaries/ancillaries are not
'locked-out', and that all plant trips have been reset.
10) Ensure that no jumpers are in place. For more
information, refer to "Jumper Log" in "Audit Checklist"
chapter.
11) Once all of the wiring has been pulled, loop checked,
and verified, the cable glands should be potted. An
audit on the completion of cable potting or
compounding of all junction boxes and/or glands
should be carried out and signed off by the Site
Manager before handover to the operator / customer.
Comments
Signatures / Date
Customer
Rolls-Royce
170
Completed Witnessed
Safety Note: This is necessary to prevent hot or com-

bustible gas from travelling through the conduit to
other package areas.
12) The GG oil tank temperature is at an approved
temperature.
ICM Signature___________________________
Please print _____________________________
Comments
Signatures / Date
Customer
Rolls-Royce
171
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
172
Completed Witnessed
Activity 167 - Start on Gas Fuel
Reference Documents
Schematic
GED00207951 - Trent 60 WLE Gas Fuel System Diagram
GTER 10210 - Master Application Installation and
Commissioning Schedule
Procedures
Reference GTER 10210 for Start on Gas Fuel instructions.
Comments
Signatures / Date
Customer
Rolls-Royce
173
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
174
Completed Witnessed
Activity 168 - Package Hot

Commissioning Off-Line
Reference Documents
TRPED 3049 - Industrial Trent Phase III Operating
Sequencing, Power Pullbacks, Alarms, CSDs, and Trips
GTER 10201 - Master Applications Installation and
Note:
For gas turbine hot commissioning, please refer to GTER
10201 - Master Applications Installation and
Commissioning Schedule. For more information, refer to
chapter "Engineering Standards, Forms, and Drawings."
For package operation, please refer to TRPED 3049 -
Industrial Trent Phase III Operating Sequencing, Power
Pullbacks, Alarms, CSDs, and Trips. For more information,
refer to chapter "Engineering Standards, Forms, and
Drawings."
Instructions
The following tests will be completed with generator off
line:
Unit test to include start up to sub sync idle
Overspeed tests at sync idle speed
Comments
Signatures / Date
Customer
Rolls-Royce
175
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
176
Completed Witnessed
Activity 169 - Perform Generator On-

Line Test
Reference Documents
Arrangement
Instruction Notes
Instructions
Perform the following tests as per vendor documentation:
1) Generator Synchronizing Test
2) Generator Load Test
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
177
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
178
Completed Witnessed
Activity 170 - Perform Generator Off-

Line Test
Reference Documents
Arrangement
Instruction Notes
1) Initial start up of unit will be with open circuit and
Generator Open circuit excitation will be checked.
2) Generator short circuit cables or bus bar must be
installed at different locations to complete the short
circuit testing.
Instructions
Perform the following tests as per vendor documentation:
1) Open circuit excitation test
2) Short circuit testing including ground fault, over-
current, differential, negative sequence.
3) Generator Phase Matching verification
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
179
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
180
Completed Witnessed
Activity 171 - Package Hot

Commissioning On-Line
Reference Documents
TRPED 3049 - Industrial Trent Phase III Operating
Sequencing, Power Pullbacks, Alarms, CSDs, and Trips
GTER 10201 - Master Applications Installation and
Note:
For gas turbine hot commissioning, please refer to GTER
10201 - Master Applications Installation and
Commissioning Schedule. For more information, refer to
chapter "Engineering Standards, Forms, and Drawings."
For package operation, please refer to TRPED 3049 -
Industrial Trent Phase III Operating Sequencing, Power
Pullbacks, Alarms, CSDs, and Trips. For more information,
refer to chapter "Engineering Standards, Forms, and
Drawings."
Instructions
The following unit tests will be performed with generator on
line:
Lube Oil Consumption test at low power
ESD at 380 PSIA P30
Lube Oil Consumption test at full power
Water Injection Test
Comments
Signatures / Date
Customer
Rolls-Royce
181
Completed Witnessed
ISI Testing
ESD at full power
Comments
Signatures / Date
Customer
Rolls-Royce
182
Completed Witnessed
Activity 172 - Fuel Transfer Tests
Reference Documents
GED00207959 - Liquid Fuel Metering System Diagram
Procedure
1) Reference GTER 10210 for Liquid to Gas Fuel
Transfer instructions. For more information, refer to
chapter "Engineering Standards, Forms, and
Drawings."
2) Reference GTER 10210 for Gas to Liquid Fuel
Transfer.
Comments
Signatures / Date
Customer
Rolls-Royce
183
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
184
Completed Witnessed
Activity 173 - Performance Test
Reference Documents
GEM 0261 - Test Procedure - Gas Turbine Package Site
Emissions and Enthalpy Testing
Procedures
GEM 0261 is the Rolls-Royce recommended site
performance pass-off test procedure.
Comments
Signatures / Date
Customer
Rolls-Royce
185
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
186
Completed Witnessed
Activity 174 - Perform CO2 and NOX

Emission Verification Test
Reference Documents
Instruction Notes
Instructions
Perform CO2 and NOX compliance testing as per job
requirements
Problems and Notes:
Comments
Signatures / Date
Customer
Rolls-Royce
187
Completed Witnessed
Comments
Signatures / Date
Customer
Rolls-Royce
188
Completed Witnessed
Activity 175 - Statement of Acceptance
Reference Documents
GEM 0170 - Installed Gas Turbine Package - User
Acceptance Test
GEMF0170.A - Statement of Acceptance (Commissioning
and Start-up)
GEMF0170.B - Statement of Acceptance (Commissioning
and Start-up Exceptions)
GEMF0170.C - Statement of Acceptance (Industrial 24
Hour Test Run)
GEMF0170.D - Statement of Acceptance (Industrial
Reliability Run)
GEMF0170.E - UAT Event Log Form
GEMF0170.F - UAT LOG Form
Instructions
Perform acceptance testing in accordance with GEM 170
and contractual obligations as per Installation
Commissioning Manager.
Note:
Ensure that no jumpers are in place. Please refer to the
chapter entitled "Audit Checklist" for further information.
Once the prior activities have been completed and signed
off, please complete GEM 0170 - Installed Gas Turbine
Package - User Acceptance Test.
Comments
Signatures / Date
Customer
Rolls-Royce
189
Completed Witnessed
Once the Statement of Acceptance has been signed and

witnessed the warranty obligations of Rolls-Royce shall
commence.
Comments
Signatures / Date
Customer
Rolls-Royce
190
Chapter 4 Safety method
statement
191
Safety method statement ro
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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)
193
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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.

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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
195
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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
199
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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 225.
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 5 Risk assessment
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204 L:\ICS\WIP\Methods\ICS Manuals\M.A606 KENKO BOLIVIA\Vol 2\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:
205
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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:

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E) F)
Foreseeable Consequence (outcome)
C) D) Hazardous cause
Hazard event (cause of G) H) J)
(potential (what hazardous Value 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.
207
Risk assessment ro
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E) F)
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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E) F)
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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E) F)
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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E) F)
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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Risk assessment ro
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E) F)
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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E) F)
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.
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Risk assessment ro
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E) F)
- 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 / Hose uids added to the
PPE:
failure when fill- water to wash the
Water wash - Long sleeve
15) Health ing / using the engine, and the
additives overalls, gloves
Hazards. Water Wash inhibiting fluids,
coming in and goggles. 6
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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E) F)
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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Risk assessment ro
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E) F)
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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E) F)
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.
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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 of M) reduction has been
actions 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.
221
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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 6 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
225
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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 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
• GER 0204 - Combined Oil System for the Trent DLE and WLE Gas Turbine Packages
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 7 Forms
227
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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
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Chapter 8 Drawings
231
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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
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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
235
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Chapter 9 Spare parts list
This chapter contains the Spare Parts list that the customer purchased
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Chapter 10 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.
243
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11)Questionnaire completed by:
Name: Company: Date:

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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
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Installation and Commissioning Services

Volume 2 Trent - Mechanical and Controls/Electrical Commissioning Information

Customer: Kenko Bolivia

Proprietary Rights Legend

Chapter 2 - Pre-commissioning Activities

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Chapter 3 - Commissioning Activities

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Activity 160 - Compressor Water Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Chapter 4 - Safety method statement

Chapter 5 - Risk assessment

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Chapter 6 - Engineering standards

Chapter 9 - Spare parts list

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2 L:\ICS\WIP\Methods\ICS Manuals\M.A606 KENKO BOLIVIA\Vol 2\intro.fm 14 May 2012

4 L:\ICS\WIP\Methods\ICS Manuals\M.A606 KENKO BOLIVIA\Vol 2\intro.fm 14 May 2012

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8 L:\ICS\WIP\Methods\ICS Manuals\M.A606 KENKO BOLIVIA\Vol 2\intro.fm 14 May 2012

America’s Region Operators

Asia Pacific Region Operators

Middle East Region Operators

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12 L:\ICS\WIP\Methods\ICS Manuals\M.A606 KENKO BOLIVIA\Vol 2\Chapter_Pre-commissioning Activities.fm 14 May 2012 1:48 pm

14 L:\ICS\WIP\Methods\ICS Manuals\M.A606 KENKO BOLIVIA\Vol 2\Chapter_Pre-commissioning Activities.fm 14 May 2012 1:48 pm

16 L:\ICS\WIP\Methods\ICS Manuals\M.A606 KENKO BOLIVIA\Vol 2\Section I_Mechanical Pre-commissioning.fm 14 May 2012

Section I Introduction: Mechanical Pre-

18 L:\ICS\WIP\Methods\ICS Manuals\M.A606 KENKO BOLIVIA\Vol 2\Section I_Mechanical Pre-commissioning.fm 14 May 2012

Activity 79 - Earthing / Grounding

GEM 0047 - Procedure for Electrical Testing of a Package

GER 0018 - Package Wiring System Engineering and

3) In the event that a step cannot be completed, the

5) All extraneous steelwork cable trays, uni-strut, junction

Instrument Clean Earth Tests

Panel Reason for Action Reading

4) 4) Continue until the overall readings are greater than

Note: Less than 0.5? would be more desirable for the

Test Points Results Comments Date

6) On completion of tests, ensure that each connection

Activity 80 - Verify operation of

Entronics Installation Manual E555-000L-0511 Vendor

Problems and Notes:

Activity 81 - Wire Check and Power-up

Energize AC power lighting circuits for each of the following

Verify proper operation of light fixtures and switches.

Problems and Notes:

Activity 82 - Wire Check and Power-up

Customer DC Power Distribution drawings

Entronics Installation Manual E555-000L-0511 Vendor

Problems and Notes:

Activity 83 - Wire Check and Power-up

GED00220838 - ECS/SIS/PCS UCP Outline

Customer AC power distribution drawings

Entronics Installation Manual E555-000L-0511 Vendor

4) Disconnect all external communications cables until

Problems and Notes:

Activity 84 - Wire Check and Power-up