TBL - 31 - E - 150b - 001 - TP - 001-0 - En-Plant Safety Valve Test Procedure With Hydraulic Lifting Device

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Owner
Owner’s Engineer: Contractor:
Project:
TAMBAK LOROK COMBINED CYCLE
POWER PLANT BLOCK 3 PROJECT
WITH NET DEPENDABLE CAPACITY OF 600 – 850 MW.
SEMARANG – CENTRAL JAVA
Subject: Plant Safety Valve Test Procedure with Hydraulic Lifting Device
Issue Purpose: Responsible Dept:

Issued for Construction PE-ACE
Originator:
Originator Document no: Document Status: Originator Rev: 0

1GP025431 Released
Project Document No.: Rev: Sheet.:
TBL/31/E/150b---001/TP/001 0 0 / 12
Issue date: 2023-01-27
Information Class, if applicable, on pg. 1 et sqq

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Revision History
Rev. Revision Issued by Checked by Released by Brief Description
Date
A 04-05-2020 P. Annegowda C. Wirth S. SUGUMARAN
0 Description current Revision

Revised as per customer comments
Owner
Owner’s Engineer: Contractor:
Project:
TAMBAK LOROK COMBINED CYCLE
POWER PLANT BLOCK 3 PROJECT
WITH NET DEPENDABLE CAPACITY OF 600 – 850 MW.
SEMARANG – CENTRAL JAVA
Subject: Plant Safety Valve Test Procedure with Hydraulic Lifting Device
Issue Purpose: Responsible Dept.: PE-ACE
Originator:
Originator Document no: 1GP025431 Document Status: Originator Rev: 0

Released
Project Document No.: Rev: Sheet.:
TBL/31/E/150b---001/TP/001 0 1/12
Issue date: 2023-01-27
© COPYRIGHT 2023 General Electric Company Non-Public
All rights reserved. The information herein is Proprietary and Technically Exclusive content that is solely owned by General Electric Company
and/or its affiliates. Thus, it is being provided with the explicit expectation of restricted and privileged use. All recipients of this information
shall be deemed to have agreed not to make duplications, reproductions of any nature by any means, modifications, disclosures, or use any
portion of this material; except as is expressly authorized in writing by the General Electric Company, and/or its legitimate affiliates.
Released
Table of Contents:
1. Objective..................................................................................................................................................3
2. Scope of Application .............................................................................................................................3
3. Responsibilities......................................................................................................................................4
3.1. HRSG Safety Valves.................................................................................................................. 4
3.2. The HRSG commissioning lead engineer has to organize and coordinate all activities ........ 4
4. Reference Documents ..........................................................................................................................4
5. Terminology, Definitions, Abbreviations...........................................................................................5
5.1. Abbreviations .............................................................................................................................. 5
5.2. Safety Symbols .......................................................................................................................... 5
6. Safety .......................................................................................................................................................6
6.1. Safety of Personnel .................................................................................................................... 6
6.2. Safety of Plant ............................................................................................................................ 6
6.2.1. HP System ..................................................................................................................... 6
6.2.2. Reheat and IP System ................................................................................................... 6
7. Test Preparation .....................................................................................................................................7
7.1. Preconditions .............................................................................................................................. 7
7.2. Plant Operation during Valve Adjustments and Testing .......................................................... 7
7.3. Temporary I&C Modifications .................................................................................................... 8
8. Safety Valve Testing ..............................................................................................................................8
8.1. Testing of HP Safety Valves ...................................................................................................... 8
8.2. Testing of Reheater Safety Valves............................................................................................ 9
8.3. Testing of IP Drum / IP Steam outlet Safety Valves ................................................................. 9
8.4. Testing of LP Safety Valves.....................................................................................................10
8.5. Restoration after Safety Valve Test completion .....................................................................10
8.6. Test Recording .........................................................................................................................10
9. Enclosure ..............................................................................................................................................11
9.1. Enclosure 1: Action List Safety Valve Testing ........................................................................11
10. Attachments..........................................................................................................................................12
10.1. Attachment 1: HRSG safety valve list (TBL/31/B/H--EN/LV/001) .........................................12
Identification Number: Rev. Date Lang. Sheet

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All rights reserved. The information herein is Proprietary and Technically Exclusive content of the General Electric Company and/or its legitimate
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1. OBJECTIVE
The purpose of this document is to ensure the safe operation of the Power Plant during safety valve
testing.
The safety valve testing will be conducted by means of a Hydraulic test device.
No live testing will be conducted and therefore no gagging of safety valves will be necessary. This
testing method ensures maximum safety regarding overpressure of steam systems.
It is not the intention of this document to interfere in the detailed test procedure and mechanical
adjustments to be made at the Safety Valves itself, which is clearly in the HRSG Safety Valve
Supplier’s scope.
2. SCOPE OF APPLICATION
This document is valid for the Tambak Lorok Combined Cycle Power Plant Block 3 Project.
Test devices are required for the following safety valves:
o HRSG HP Safety Valves
o HRSG Reheater Safety Valves
o HRSG IP Safety Valves
o HRSG LP Safety Valves
Following steam safety valves shall be adjusted and tested:
• HRSG HP parts:
o HP drum safety valve No.1 & No.2: HAH50AA190/191
o HP Steam outlet safety valve: LBA50AA190
• HRSG Reheater parts:
o Cold reheat steam inlet safety valves No.1 & No.2: LBC30AA190/191
o Hot reheat steam outlet safety valve: LBB40AA190
• HRSG IP parts:
o IP drum safety valve No.1 & No.2: HAD30AA190/191

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o IP Steam super heater outlet safety valve: LBA30AA190
• HRSG LP parts:
o LP drum safety valve No.1 & No.2: HAD10AA190/191
o LP Steam outlet safety valve: LBA10AA190
3. RESPONSIBILITIES
The Operation of the Plant during the safety valves testing is under the responsibility of the GE
Commissioning Lead Engineer.
GE personnel will operate the plant at a load/pressure level according to the requirements from the
safety valve Company responsible.
The safety valve company responsible is in charge for the execution of the safety valve testing by
means of a Hydraulic Test device.
3.1. HRSG Safety Valves
The HRSG commissioning lead engineer has to organize and coordinate all activities.
The HRSG safety valve supplier responsible is liable for the execution of the safety valve testing by
3.2. The HRSG commissioning lead engineer has to organize and coordinate all activities
The HRSG safety valve supplier responsible is liable for the execution of the safety valve testing by
4. REFERENCE DOCUMENTS
Book II Tambak Lorok Tech Rqmts Contract
Book III_Appendix 7_Functional Tests Contract
Valve List_1 TBL/31/B/H--EN/LV/001
Input Data for Functional and Logic Diagram TBL/31/B/H--EN/LO/001

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5. TERMINOLOGY, DEFINITIONS, ABBREVIATIONS
5.1. Abbreviations
GE General Electric
bara bar absolute [105 Pa]
EHS Environmental, Health and Safety
GT Gas Turbine
HRSG Heat Recovery Steam Generator
HP High pressure
IP Intermediate pressure
LP Low pressure
PLS (T) Protective Load Shedding (with Trip)
ST Steam Turbine
WSC Water and Steam Cycle
ITPL Inspection and Test Plan
5.2. Safety Symbols
The User should understand the following symbols used within this document:
DANGER
Danger indicates an imminently hazardous situation, which if not avoided, will result in death
or serious injury. This signal word is to be limited to the most
extreme situations.
WARNING
Warning indicates a potentially hazardous situation, which if not avoided, could result in death
or serious injury.

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CAUTION
Caution indicates a potentially hazardous situation, which if not avoided, may result in minor
or moderate injury.
It may also be used to alert against unsafe practices.
Note
Note indicates an important instruction or the best practices
It may also be used to alert against mechanical damage to the equipment
6. SAFETY
The project EHS policy must strictly be followed during all safety valve test activities.
6.1. Safety of Personnel
The safety of personnel takes priority over all other factors.

With a HRSG under pressure, safety valve opening can be hazardous and therefore only qualified
personnel should be in the valve vicinity. The area around the safety valves and escape pipe work
must be marked off and suitable warning notices displayed.
Safe access to the safety valves (access platforms) with alternative access and escape route for
emergency case must be ensured.
High noise levels could be generated during the safety valve testing and therefore test team
personnel must wear ear protection throughout the whole safety valve adjustment and testing
process.
6.2. Safety of Plant
6.2.1. HP System
In case of HP bypass failure and therefore increase of HP system pressure a GT trip will be initiated.
These protection measures are already implemented in the control logic and no temporary I & C
modifications are required.
6.2.2. Reheat and IP System
In case of IP bypass failure and therefore increase of pressure in the Reheat and IP system, GT trip
will be initiated when HRH inlet or outlet pressure exceeds the set point value. The HP bypass CRH
max pressure limiter will close the HP bypass valve and limit the pressure within the CRH system
(HP Bypass Control Valve has to be in automatic).

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Note
Should for any reason the pressure in a circuit (HP, IP, LP) rise above protection level and the
plant is still in operation (no PLS or TRIP initiated), then the GT’s have to be manually tripped
over the push button in the control.
7. TEST PREPARATION
7.1. Preconditions
• All temporary cleaning equipment removed. The plant must be restored as for permanent
operation.
• All safety valves, exhaust pipe, drain lines and silencer must be inspected for integrity. Check
especially the concordance between valve location, serial number and quality documentation.
• Ensure free expansion of safety valves and their exhaust system.
• DCS and instrumentation must be commissioned and fully operational.
• Plant protection must be tested and fully available. All measurements relevant for protection
must commissioned and fully operational.
• Required inspection and test personnel available.
• Adequate hydraulic set pressure device available.
• All test paperwork for recording set pressure available.
• All necessary public and local authorities are notified of potential high noise emissions.
• All safety precautions according site EHS policy are in place.
7.2. Plant Operation during Valve Adjustments and Testing
The Power Plant shall be operated in Bypass operation in the proper range capacity in order to
have sufficient system base pressure, allowing conducting the valve adjustments and testing.
For each safety valve test, the required test pressure is to be defined in relation with its set point
according to the HRSG Safety Valve Supplier’s Test Procedure. Verify that the latest confirmed
revision regarding set pressure of safety valve is considered.
The testing sequence should in any case be defined and agreed between all involved parties
prior starting testing activities.
Communication between the testing crew and the operators in the control room has to be
ensured.

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The GE Commissioning Lead Engineer for the Water and Steam Cycle does ensure that the
power plant is always operated within allowed operating ranges and protective equipment is
fully active.
7.3. Temporary I&C Modifications
No temporary I&C modifications are required.
DANGER
• Under no circumstances, the protective software measures of the power plant protection
matrix shall be deactivated, nor forced or simulated!
• Under no circumstances, the safety valves of the HRSG shall be mechanically forced to closed,
blind flanged, nor blocked in any kind!
• All Protection equipment shall be fully active throughout the whole testing/adjustment
period of the safety valves!
8. SAFETY VALVE TESTING
8.1. Testing of HP Safety Valves
For the testing of the HP safety valves the required system pressure is approx. 75% of the set
pressure:
o For the 1st HP Separator Safety Valve (HAH50AA190) the recommended testing pressure
is 162.75 barg (217 barg*0.75).
o For the 2nd HP Separator Safety Valve (HAH50AA191) the recommended testing pressure
is 167.62 barg (223.5 barg*0.75).
o For the HP Superheater Outlet Safety Valve (LBA50AA190) the recommended testing
pressure is 153.37 barg (204.5 barg*0.75).
Set the GT load to a value that the resulting steam pressure is near the desired values. Try e.g. GT
hold point (HP4).
If needed, adjust the steam pressure via the HP bypass set point station (Control valve in automatic
mode).
Increase the GT load in case the HP Bypass control valve reaches the minimum opening of approx.
50%.
After testing the set point has to be normalized.

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8.2. Testing of Reheater Safety Valves
For the testing of the reheater safety valves the required system pressure is approx. 75% of the set
pressure:
o For the 1st reheater inlet safety valves (LBC30AA190), the recommended testing pressure
is 31.42 barg (41.9 barg*0.75)
o For the 2nd reheater inlet safety valves (LBC30AA191), the recommended testing pressure
is 32.4 barg (43.2 barg*0.75)
o For the reheater outlet safety valves (LBB40AA190), the recommended testing pressure is
30.75 barg (41 barg *0.75)
hold point (HP4).
If needed, adjust the steam pressure via the IP bypass set point station (Control valve in automatic
mode).
Increase the GT load in case the IP Bypass control valve reaches the minimum opening of approx.
50%.
8.3. Testing of IP Drum / IP Steam outlet Safety Valves
For the testing of the IP Drum - and IP Steam outlet safety valves the required system pressure is
approx. 75% of the set pressure:
o For the 1st IP drum safety valve (HAD30AA190), the recommended testing pressure is 33.07
barg (44.1 barg*0.75)
o For the 2nd IP Drum Safety Valve (HAD30AA191), the recommended testing pressure is
34.05 barg (45.4 barg*0.75)
o For the IP Steam Outlet Safety Valve (LBA30AA190), the recommended testing pressure is
32.25 barg (43 barg*0.75)
hold point (HP4).
If needed, adjust the steam pressure via the IP bypass set point station (control valve in automatic
mode).
IP steam outlet control valve should be fully open (results from automatic control).
Increase the GT load in case the IP Bypass control valve reaches the minimum opening of approx.
50%.

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8.4. Testing of LP Safety Valves
For the testing of the LP safety valves the required system pressure is approx. 75% of the set
pressure:
o For the 1st LP Drum Safety Valve (HAD10AA190) the recommended testing pressure is
9.37 barg (12.5 barg * 0.75)
o For the 2nd LP Drum Safety Valve (HAD10AA191) the recommended testing pressure is
9.75 barg (12.9 barg*0.75)
o For the LP Steam Outlet Safety Valve (LBA10AA190) the recommended testing pressure is
9 barg (12 barg*0.75)
hold point (HP4).
If needed, adjust the steam pressure via the LP bypass set point station (Control valve in automatic
mode).
Increase the GT load in case the LP Bypass control valve reaches the minimum opening of approx.
50%.
8.5. Restoration after Safety Valve Test completion
After the Safety Valves have been successfully adjusted and tested, all temporary equipment used
for valve adjustment and testing has to be removed.
8.6. Test Recording
Test records (Test certificates) shall be filled out for each safety valve test.
A copy of this Test records shall be handed over to all involved parties.

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9. ENCLOSURE
9.1. Enclosure 1: Action List Safety Valve Testing
Plant
Set Plant Protection
Test Pressure Protection
point (Automatic)
(Manual)
Description KKS [bara] [bara] Adjust pressure by [bara] [bara]
Increase HP bypass set 230

point or manually close HP GT 3x runback and GT
Bypass Control Valve shutdown at idle after 3 231
HP Drum Safety Vlv No. 1 HAH50AA190 217 122.2 second delay Trip manually
Bypass Control Valve shutdown at idle after 3 231
HP Drum Safety Vlv No. 2 HAH50AA191 223.5 125.9 second delay Trip manually
HP Steam Outlet Safety Bypass Control Valve shutdown at idle after 3 231
Vlv LBA50AA190 204.5 116.6 second delay Trip manually
Increase IP bypass set point 46.7
or manually close IP Steam GT 3x runback and GT
Outlet Control Valve shutdown at idle after 3 47.7
IP Drum Safety Vlv No. 1 HAD30AA190 44.1 30.75 second delay Trip manually
IP Drum Safety Vlv No. 2 HAD30AA191 45.4 31.65 second delay Trip manually
IP Steam Outlet Safety Vlv LBA30AA190 43 28.5 second delay Trip manually
or manually close IP Bypass GT 3x runback after 30 40.8
RH Steam Inlet SV No. 1 LBC30AA190 41.9 28.5 Control Valve second delay Trip manually
or manually close IP Bypass GT 3x runback after 30 40.8
RH Steam Inlet SV No. 2 LBC30AA191 43.2 28.5 Control Valve second delay Trip manually
Increase IP bypass set point
or manually close IP Bypass
RH Steam Outlet SV LBB40AA190 41 26.25 Control Valve N/A
Manually close LP Bypass 13.3 14.3
Control Valve GT 3x runback and GT
shutdown at idle after 3 Trip manually
LP Drum Safety Vlv No. 1 HAD10AA190 12.5 7.5 second delay
LP Drum Safety Vlv No. 2 HAD10AA191 12.9 7.72 second delay
LP Steam Outlet Safety Vlv LBA10AA190 12 6.75 second delay

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10. ATTACHMENTS
10.1. Attachment 1: HRSG safety valve list (TBL/31/B/H--EN/LV/001)

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Space for Stamp: IP/OE

Issued for Construction B

Description current Revision

Owner’s Engineer: Contractor:

Issue Purpose: Responsible Dept:

Originator Document no: Document Status: Originator Rev: 0

Issue date: 2023-01-27

Information Class, if applicable, on pg. 1 et sqq

0 Description current Revision

Owner’s Engineer: Contractor:

Issue Purpose: Responsible Dept.: PE-ACE

Originator Document no: 1GP025431 Document Status: Originator Rev: 0

© COPYRIGHT 2023 General Electric Company Non-Public

Identification Number: Rev. Date Lang. Sheet

Test devices are required for the following safety valves:

o HRSG HP Safety Valves

o HRSG Reheater Safety Valves

o HRSG IP Safety Valves

o HRSG LP Safety Valves

Following steam safety valves shall be adjusted and tested:

o HP drum safety valve No.1 & No.2: HAH50AA190/191

o HP Steam outlet safety valve: LBA50AA190

• HRSG Reheater parts:

o Hot reheat steam outlet safety valve: LBB40AA190

o IP drum safety valve No.1 & No.2: HAD30AA190/191

Identification Number: Rev. Date Lang. Sheet

o IP Steam super heater outlet safety valve: LBA30AA190

o LP drum safety valve No.1 & No.2: HAD10AA190/191

o LP Steam outlet safety valve: LBA10AA190

3.1. HRSG Safety Valves

Book II Tambak Lorok Tech Rqmts Contract

Book III_Appendix 7_Functional Tests Contract

Valve List_1 TBL/31/B/H--EN/LV/001

Input Data for Functional and Logic Diagram TBL/31/B/H--EN/LO/001

Identification Number: Rev. Date Lang. Sheet

5. TERMINOLOGY, DEFINITIONS, ABBREVIATIONS

bara bar absolute [105 Pa]

EHS Environmental, Health and Safety

HRSG Heat Recovery Steam Generator

PLS (T) Protective Load Shedding (with Trip)

WSC Water and Steam Cycle

ITPL Inspection and Test Plan

5.2. Safety Symbols

Identification Number: Rev. Date Lang. Sheet

6.1. Safety of Personnel

The safety of personnel takes priority over all other factors.

6.2. Safety of Plant

6.2.2. Reheat and IP System

Identification Number: Rev. Date Lang. Sheet

• Ensure free expansion of safety valves and their exhaust system.

• DCS and instrumentation must be commissioned and fully operational.

• Required inspection and test personnel available.

• Adequate hydraulic set pressure device available.

• All test paperwork for recording set pressure available.

• All safety precautions according site EHS policy are in place.

7.2. Plant Operation during Valve Adjustments and Testing

Identification Number: Rev. Date Lang. Sheet

7.3. Temporary I&C Modifications

No temporary I&C modifications are required.