Testing and Commissioning Schedule

Table of Contents

Overview

The Testing and Commissioning Phase is the final technical phase before commercial operation of the CCPP. This phase typically spans 3-6 months and involves systematic testing of all plant systems, culminating in performance testing and handover.

IDActivityDuration (weeks)PredecessorsResourcesDeliverables
T1Commissioning Team Mobilization4C45Commissioning Manager, TeamCommissioning Plan
T2Commissioning Procedures Development6T1Commissioning EngineersCommissioning Procedures
T3Commissioning Safety Plan Development3T1Safety Engineer, Commissioning ManagerCommissioning Safety Plan
T4Instrument Air System Pre-commissioning2C60Commissioning TeamSystem Pre-commissioning Report
T5Service Water System Pre-commissioning2C60Commissioning TeamSystem Pre-commissioning Report
T6Fire Protection System Pre-commissioning2C60Commissioning Team, Fire Protection VendorSystem Pre-commissioning Report
T7Electrical Distribution System Pre-commissioning3C60Electrical Commissioning EngineersSystem Pre-commissioning Report
T8DC System Pre-commissioning2C60Electrical Commissioning EngineersSystem Pre-commissioning Report
T9UPS System Pre-commissioning2C60Electrical Commissioning EngineersSystem Pre-commissioning Report
T10Control System Pre-commissioning4C60, T7, T8, T9Control System Engineers, VendorSystem Pre-commissioning Report
T11Cooling Water System Pre-commissioning3C60, T5Mechanical Commissioning EngineersSystem Pre-commissioning Report
T12Water Treatment System Pre-commissioning3C60, T5Mechanical Commissioning Engineers, VendorSystem Pre-commissioning Report
T13Fuel Gas System Pre-commissioning3C60, T4Mechanical Commissioning EngineersSystem Pre-commissioning Report
T14HVAC System Pre-commissioning2C60, T4, T7Mechanical Commissioning EngineersSystem Pre-commissioning Report
T15Auxiliary Systems Pre-commissioning4T4, T5, T7Commissioning TeamSystem Pre-commissioning Report
T16Gas Turbine Pre-commissioning4T10, T13, T15GT Vendor, Commissioning TeamGT Pre-commissioning Report
T17HRSG Pre-commissioning4T10, T11, T15HRSG Vendor, Commissioning TeamHRSG Pre-commissioning Report
T18Steam Turbine Pre-commissioning4T10, T11, T15ST Vendor, Commissioning TeamST Pre-commissioning Report
T19Generator and Electrical Systems Pre-commissioning3T7, T16, T18Electrical Commissioning EngineersGenerator Pre-commissioning Report
T20DCS Final Check and Testing3T10, T16, T17, T18Control System Engineers, VendorDCS Testing Report
T21Electrical System Energization2T7, T19Electrical Commissioning EngineersEnergization Report
T22Chemical Cleaning of HRSG and Steam Systems3T17Commissioning Team, Specialty ContractorChemical Cleaning Report
T23Steam Blowing4T22Commissioning TeamSteam Blowing Report
T24Fuel Gas System Commissioning2T13Commissioning TeamSystem Commissioning Report
T25Gas Turbine First Fire1T16, T20, T24GT Vendor, Commissioning TeamFirst Fire Report
T26Gas Turbine Commissioning3T25GT Vendor, Commissioning TeamGT Commissioning Report
T27HRSG Commissioning3T17, T22, T23, T26HRSG Vendor, Commissioning TeamHRSG Commissioning Report
T28Steam Turbine Roll and Synchronization2T18, T27ST Vendor, Commissioning TeamST Synchronization Report
T29Steam Turbine Commissioning3T28ST Vendor, Commissioning TeamST Commissioning Report
T30Combined Cycle Integration2T26, T29Commissioning TeamIntegration Report
T31Plant Control System Tuning3T30Control System Engineers, VendorControl System Tuning Report
T32Plant Reliability Run (24 hours)1T31Commissioning TeamReliability Run Report
T33Plant Reliability Run (72 hours)1T32Commissioning TeamReliability Run Report
T34Performance Test Preparation2T33Performance Test Engineer, Commissioning TeamTest Procedures
T35Gas Turbine Performance Testing1T34Performance Test Engineer, GT VendorGT Performance Test Report
T36Steam Turbine Performance Testing1T34Performance Test Engineer, ST VendorST Performance Test Report
T37HRSG Performance Testing1T34Performance Test Engineer, HRSG VendorHRSG Performance Test Report
T38Combined Cycle Performance Testing2T35, T36, T37Performance Test Engineer, Commissioning TeamPlant Performance Test Report
T39Emissions Testing1T38Environmental Engineer, Third Party TesterEmissions Test Report
T40Noise Testing1T38Environmental Engineer, Third Party TesterNoise Test Report
T41Plant Trip and Recovery Testing1T38Commissioning TeamTrip and Recovery Test Report
T42Grid Code Compliance Testing2T38Electrical Commissioning Engineers, Grid OperatorGrid Compliance Report
T43Completion of Commissioning Punch List3T39, T40, T41, T42Commissioning TeamResolved Punch List
T44Operations Training6T1Training Engineer, Operations TeamTraining Completion Report
T45Operations Readiness Review2T44, T43Operations Manager, Commissioning ManagerReadiness Review Report
T46Preparation of Commissioning Documentation4T43Commissioning Engineers, Document ControlCommissioning Documentation
T47Provisional Acceptance Certificate1T45, T46Project Manager, ClientProvisional Acceptance Certificate
T48Handover to Operations2T47Commissioning Manager, Operations ManagerHandover Documentation
T49Commercial Operation0T48Project Manager, Operations ManagerCommercial Operation Certificate
Milestone IDDescriptionSchedule Date (weeks from commissioning start)
TM1Commissioning Team MobilizedWeek 4
TM2Commissioning Procedures ApprovedWeek 10
TM3Auxiliary Systems Pre-commissioning CompleteWeek 20
TM4Gas Turbine First FireWeek 28
TM5Steam Turbine Synchronized to GridWeek 36
TM6Combined Cycle Integration CompleteWeek 41
TM772-Hour Reliability Run CompleteWeek 45
TM8Performance Testing CompleteWeek 50
TM9Commissioning Punch List ClosedWeek 53
TM10Provisional Acceptance Certificate IssuedWeek 58
TM11Commercial Operation DateWeek 60

Pre-commissioning activities involve checking individual components and systems before energization or introduction of process fluids:

  1. Mechanical Systems

    • Alignment checks
    • Rotation checks
    • Lubrication system checks
    • Valve operation verification
    • Strainer and filter installation verification
    • Expansion joint inspection

  2. Electrical Systems

    • Insulation resistance testing
    • Continuity testing
    • Relay testing and calibration
    • Transformer testing
    • Switchgear testing
    • Motor testing

  3. Control Systems

    • Loop checks
    • Signal verification
    • Instrument calibration
    • Control logic verification
    • HMI functionality testing
    • Alarm system testing

  4. Piping Systems

    • Pressure testing completion verification
    • Cleaning and flushing verification
    • Support and hanger inspection
    • Expansion provision verification
    • Valve positioning verification

Commissioning activities involve energizing systems and introducing process fluids for functional testing:

  1. Utility Systems

    • Instrument air system
    • Service water system
    • Fire protection system
    • HVAC system
    • Electrical distribution system

  2. Major Equipment

    • Gas turbine commissioning
    • HRSG commissioning
    • Steam turbine commissioning
    • Generator commissioning
    • Water treatment system

  3. Integrated Systems

    • Combined cycle integration
    • Plant control system tuning
    • Load testing
    • Reliability testing
    • Performance optimization

Performance testing verifies that the plant meets contractual guarantees:

  1. Test Parameters

    • Power output
    • Heat rate
    • Emissions levels
    • Start-up times
    • Ramp rates
    • Noise levels

  2. Testing Methodology

    • ASME PTC 46 (Overall Plant Performance)
    • ASME PTC 22 (Gas Turbine Performance)
    • ASME PTC 6 (Steam Turbine Performance)
    • ASME PTC 4.4 (HRSG Performance)
    • EPA Methods (Emissions Testing)

  3. Test Conditions

    • Base load operation
    • Part load operation
    • Ambient temperature correction
    • Grid frequency variations
    • Fuel composition variations

  1. Acceptance Criteria

    • Performance guarantees met
    • Emissions compliance verified
    • Reliability demonstrated
    • Operations training completed
    • Documentation delivered
    • Punch list items resolved

  2. Handover Documentation

    • As-built drawings
    • Operating manuals
    • Maintenance manuals
    • Test reports
    • Commissioning records
    • Warranty certificates

  3. Regulatory Approvals

    • Environmental compliance certification
    • Electrical grid compliance certification
    • Safety certification
    • Operating permits

  4. Commercial Handover

    • Provisional acceptance certificate
    • Performance security release
    • Warranty period commencement
    • Final payment milestone
    • Commercial operation declaration

This testing and commissioning phase schedule provides a comprehensive framework for systematically testing and verifying all aspects of a combined cycle power plant, ensuring it meets performance guarantees and is ready for commercial operation.