PG TEST PROCEDURE

Project : GMR CHHATTISGARH ENERGY LTD

Package : 2 X 685 MW Thermal Power Plant at

Raipur, Chhattisgarh.

Agency : L & T ECC Division

LOI No : CTPP/BOP/CHP-01

NTP No : CTPP/BOP/CHP-02

1.1.0 STANDARD GUARANTEE, ACCEPTANCE TEST & TESTING PROCEDURE

FOR COAL HANDLING PLANT.

1.00.1 On successful completion of reliability operation of plant, the contractor shall notify in
writing to the owner that the plant is ready for doing performance test. Accordingly the plant
will be taken over by the owner and shall issue a commissioning certificate within 7 days’
time.

1.00.2 The owner shall furnish at its own expense suitable skilled and unskilled operators and all
electrical power, water, materials consumable items, facilities and infra-structure, and other
goods and services necessary to conduct performance acceptance tests on receiving notice
from the contractor. All kinds of special measuring and testing instruments will be arranged
by the contractor.

1.00.3 At the conclusion of the Performance Acceptance Test, the Supplier shall demonstrate to the
owner the guaranteed performance parameters as set out in clause No. 9.04.00 FLOW PATH
CAPACITY.

1.00.4 If the guaranteed performance for the Performance Acceptance Test specified in 9.04.00
hereto has not been met the supplier shall, at its expense correct any deficiency, repair or
replace the defective parts of the Equipment at Site within a reasonable period of time.
Immediately after completion of any correction, repair or replacement, the entire Performance
Acceptance Test shall be repeated in the same manner as the first Performance Acceptance
Test, which had failed and the guaranteed performance parameters shall be demonstrated.

1.1.0 RELIABILITY OPERATION

1.01.01 After the initial operations, the plant shall be on reliability operation. During the reliability
operation, the Contractor will be allowed to make minor adjustments as may be necessary,
provided that such adjustments do not interfere with or prevent the commercial use of the
plant or result in significant reduction of output or increase of the heat rate of the plant. The
duration of the reliability operation of plant shall be spread over a period of THIRTY (30)
days at different load regimes in automatic mode out of which it shall be operated
continuously for at least two hundred and forty (240) hours at full load or any other load as
agreed by OWNER. The maximum number of interruption attributable to CONTRACTOR
shall be maximum four (4) numbers not exceeding four hours duration.

1.01.02 For the period of reliability operation the time of actual operation shall be counted. In case the
duration of actual continuous operation of any of the above modes is discontinued for reasons,
which are not due to Contractor’s fault or negligence, that particular test would be deemed to

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have satisfied the reliability operation test. However, should the test be discontinued due to
Contractor’s fault, the test shall be restarted for that particular case.

1.01.03 Should any failure (other than of an entirely minor nature) due to or arising out of faulty
design, materials, or workmanship (but not otherwise) occur in any item of the plant,
sufficient to prevent commercial use of the plant, the reliability test period of thirty (30) days
shall recommence for that item after the defect has been remedied by the CONTRACTOR.

1.01.04 A ‘reliability operation’ report comprising observations and recordings of various parameters
measured in respect of the ‘reliability operation’ shall be prepared and submitted to the
Owner / Engineer. This report, besides recording the details of various observations during
‘reliability operation’ shall also include the dates of start and finish of the reliability operation
and shall be signed by the representatives of both the parties. The report shall have recordings
of all details of interruptions that occurred, adjustments made and any repairs done during the
‘reliability operation’.

Should any failure or interruption in any portion of the tests due to or arising from faulty
design, materials, workmanship, omissions, incorrect erection, or inadequate instructions by
the Contractor’s supervisors, sufficient to prevent safe commercial use of the plant occur, the
reliability operation test at the particular load shall be considered void and the reliability test
shall recommence after the Contractor has remedied the cause of the defect.

1.01.05 The ‘reliability operations’ shall be considered successful, provided that each item of plant
can meet the above requirements. Upon the completion of ‘reliability operations’, as soon as
practicable, or at such time as may be otherwise agreed to by the parties concerned, the
Contractor shall notify in writing to the Owner / Engineer that the plant is ready for
performance tests.

1.02.00 PERFORMANCE TESTS

1.02.01 The performance tests shall be conducted at site for each unit and all major systems by the
Contractor. The Contractor’s commissioning Engineers shall make the plant ready for such
tests and assist the Owner in operation during the tests. The test will be commenced after the
‘Plant / Equipment’ has attained stable operation at the end of ‘Reliability operation’. The
date of commencement of the performance tests shall be as soon as practicable on completion
of the ‘reliability operations’ or as may be mutually agreed upon between the Contractor and
Owner.

1.02.02 The Owner reserves his right to appoint an independent inspector at his own cost as his
representative to discuss the test program, to approve the instrumentation, to witness the tests
and to analyze the test results.

1.02.03 The tests shall be binding on both the parties of the ‘Contract’ to determine compliance of the
‘Plant / Equipment’ with the performance guarantees. No separate performance tests need be
done on equipment which is already tested at shop.

1.02.04 The following unit characteristics tests shall also be conducted during performance test.
i) Trip of each major equipment, including demonstration of auto operation of standby
equipment, to be developed and mutually agreed upon in the testing procedure.

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ii) Performance of all major equipment test procedure, including the definition of the
calculation method to be used, the instrumentation to be installed, the instrument
accuracy classes, the areas of responsibility and the items which specifically require
preparation and agreement shall be submitted by the Contractor for review and
approval by the Owner / Engineer.

iii) All test instrumentation for the performance tests as required shall be supplied by the
Contractor on loan basis. All costs associated with the supply, calibration, installation
and return of the test instrumentation / data loggers / computers etc. are deemed to
have been included in the contract price. The test shall be in accordance with those
specified or as per agreed performance test codes. Batch calibration will not be
accepted.

iv) Any special equipment, tools and tackles required for successful completion of the
performance tests shall be provided by the Contractor.

v) It is the Contractor’s responsibility to co-ordinate for suitably carrying out the

performance tests. The duration of the test shall be in accordance with the agreed test
codes.

vi) The equipment/systems parameters during the performance test shall be adjusted as
far as practicable to the guaranteed performance test conditions. The tests shall be
conducted to prove guaranteed parameters as defined in the contract.

1.02.05 REPORTING OF TEST RESULTS

Within two weeks after the conclusion of the performance test and unit characteristics tests,
the Contractor shall submit a test report to the Owner with a copy submitted to the Engineer
stating:
(a) In the case of a performance test, whether the unit passed or failed such test, accompanied by
sufficient test data and calculations to demonstrate the level of performance attained with
respect to each of the tested parameters.
(b) In case of a unit characteristics tests, the level of performance achieved with respect to the
desired levels of performance.
The report(s) shall include as a minimum, the following:
(i) Description of the test procedures
(ii) Standards that were used
(iii) Instrumentation details and calibration
(iv) Full schematic diagrams with indication of instrument test location and identification tag of
same.
(v) Test logs and summary of test readings used for performance calculations
(vi) Full set of correction curves
(vii) Computation of test results.
(viii) Computations to prove measurement uncertainty is within acceptable limits.
(ix) Conclusions of performance tests: test passed or not

Within fifteen (15) days of receipt such test report(s), the Owner shall submit a notice to the

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Contractor with a copy submitted to the Engineer, stating either:

(a) That Owner concurs with the information provided in the Contractor’s test report(s), or
(b) That Owner disputes some or all of the information provided in the Contractor’s test report(s),
the areas being disputed, and the levels of performance being disputed.
If Owner concurs with the information in the Contractor’s test report(s), the Owner shall,
within fifteen (15) days of receipt of the test report, provide a written notice to the Contractor
accepting the results of the tests.

If Owner disputes any or all of the results contained in the Contractor’s test report(s),
representatives of the Contractor, Owner and the Engineer shall meet within fifteen (15) days
of the receipt of the Owner’s notice at a mutually acceptable location to review and discuss
the dispute.

1.02.06 NOTICE OF TESTS

In relation to each unit, the Contractor shall give to the Engineer and Owner TWENTY ONE
(21) days’ notice of the date after which he will be ready to make the tests on completion (the
“Tests”) and the Contractor shall commence the tests promptly thereafter. Any data obtained
in respect of Gross Heat Rate and Net Power Output prior to the commencement of the Tests
in relation to the Performance Guarantees shall not be used to assess whether the Performance
Guarantees have been attained.

1.02.07 TIME FOR TESTS

If the Engineer fails to appoint a time after having been asked to do so, or the Engineer or the
Owner do not attend at the time and place appointed, the Contractor shall be entitled to
proceed with the test in his or their absence. The tests shall then be deemed to have been made
in the presence of the Engineer and the Owner. The Contractor shall forward to the Engineer
and the Owner duly certified copies of the results of the tests.

1.3.0 FLOW PATH CAPACITY (As per contract duly guaranteed by L & T)

1. Flow Path I CAPACITY

Crushed Coal Stock Pile to Boiler Bunkers via Stackers 2000 TPH
(Comprising of SR 1\2, BC 4A\4B, BC 5A\5B, BF 1/2, BC 6A\6B, BC 7A\7B, TTR1\2).

2. Flow Path 2

Wagon tippler 3 to Crushed Coal Stockpiles 2000 TPH

(Comprising of Wagon tippler#3, Apron feeders, Dribble Conveyors, BC 1A/1B, BF 8/9,BC
2A/2B, VGF1/2, CRS 1\2, BF 3/4/5/6, BC 4A/4B, SR 1/2).

3. Flow Path 3

Wagon tippler# 1&2 to Crushed Stockpile#2 via Reclaim Hopper 2000 TPH
(Comprising of Wagon tipplers, Apron feeders, Dribble Conveyors, BC 1A/1B, BF 8/9,BC 2A/2B,
VGF1/2, CRS 1\2, BF 3/4/5/6, BC 5A\5B, BF 1/2, BC 6A\6B, BC 7A\7B, TTR1\2)

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1.3.1 Major Equipment Capacity

Guaranteed capacity of all the major equipment as identified shall be established separately by
operating individual equipment out of the two of a set at a time. Following equipment shall be
considered:

EQUIPMENT CAPACITY
Paddl . 1. Wagon Tippler 25 Tips/Hour

2. Side Arm Charger 5800 T

3. Wagon Shifter 140 T

4. Apron Feeder 2000 TPH

5. Grizzly Feeder 2000 TPH

6. Ring granulator crusher 2000 TPH

7. Stacker-cum-Reclaimer 2000 TPH

1.3.2 Power consumption

Total power consumption of all the equipment including auxiliaries with single stream
operation at its guaranteed flow path capacity except.

 Lighting

 Hoists

 Coal Sampling unit

 Sump pumps

 Elevators

 DS, DE, Ventilation, SW System, Portable Water system

2.00.00 GUARANTEE TEST PROCEDURE

1. Guaranteed performance parameters of the equipment shall be finally proved by the

performance guarantee tests. An agreement on procedure of guarantee test shall be prepared
by the representatives of Contractor, Consultant and Owner. The equipment shall be
considered as accepted by Owner from the quality points of view after the guaranteed
parameters are proved by the tests and the documents pertaining to the performance guarantee

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tests shall be signed by both parties. Trial operation should be performed as per consultant/
owners approved format of L & T BMH before PG test.

2. In case of the unsatisfactory results of Performance Guarantee tests, representatives of all the
parties to the contract shall agree upon appropriate terms & time of carrying out the repairs or
adjustments and/or replacement necessary for the achievements of guaranteed parameters.
The guarantee tests will be repeated under same conditions after carrying out the repairs or
adjustments and/or replacement as stated in previous paragraph.

3. Other than operating staff, all engineers for Guaranteed Performance Test of Coal Handling
Plant shall be deployed as well as testing equipment/ apparatus to the job site by Contractor
on returnable basis within this Contract and Price.

4. The coal handling system from Wagon Tippler to Coal yard or bunker feeding shall operate
continuously at designed capacity as specified over a period of FOUR (4) hours.

5. Prior to commencement of performance Test, Contractor shall furnish the calibration

certificate of reputed Institute to Owner duly illustrating their validation period of the
instruments being used during test.

6. Successful PG Test shall mean Owner’s acceptance of PG Test report submitted by

Contractor.

2.01.00 PRE-REQUISITES FOR PERFORMANCE & GUARANTEE TESTS

2.01.01 The prerequisites to be ensured by L&T Power Ltd and L&T BMH prior to start of the
tests are listed as Appendix-I and Appendix-II separately.

2.01.02 After successful completion of Trial Operation and commissioning, the plant shall be jointly
inspected by GMR and L & T BMH and a joint protocol shall be signed that the plant is fit for
P&G tests.

2.02.01 FLOW PATH CAPACITY TESTS

(a) All above streams formed shall be independently tested for performance & guarantee. Further,
the equipment/conveyors (except common equipment) used for performance testing of one
stream shall not be used for performance testing of the other stream.

(b) In case of direct flow path, guarantee test should include operation of all the trippers. However,
for measurement of guaranteed power consumption, farthest trippers shall be operated.

(c) While operating in stacking path, stacking will be done near the drive House end of the yard
conveyor so that the conveyor is tested under fully loaded conditions. While operating in
reclaiming path, Stacker / Reclaimer shall be near tail end of yard conveyor.

(d) While operating guaranteed capacity of the flow paths, non-spillage of coal and non-choking of
chute / equipment shall be demonstrated as indication of smooth continuous flow through the
conveyor system.

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2.02.02 POWER CONSUMPTION MEASUREMENT

i) The guaranteed power consumption as total sum of all equipment as specified shall be measured
during capacity test of the identified flow paths for both streams separately.

The load of the following items shall not be considered during measurement of power
consumption for guarantee:

· Lighting
· Hoists
· Sump Pump
· Coal Sampling Unit
· Elevator
· DE, DS, Ventilation, Potable water & SW system

ii) Measurement Terminal(s)

The guaranteed power consumption for entire Flow path(s) shall be taken during capacity test as
sum of the power consumption at the following terminals.

(1.) 3.3/6.6/ 11 KV CHP Incoming Terminals.

(2.) 415 V CHP MCC incoming terminals.
(3.) Switchgear terminal of any load connected to Employer's Switch gear.

Further the power consumption for the equipment being fed from CHP board / LT board but not
to be considered for guaranteed power consumption shall be measured separately at their
respective MCC / LT & HT switchgear input terminals and shall be subtracted from total power
consumption measured. However, if conditions permit, such equipment may not be operated
during power measurement duration.

For Stacker/ Reclaimer machine, the average power consumption shall be measured through
energy-meter at HT switchgear feeder of Stacker / Reclaimer. For conveyors, the power
consumption shall be measured at their respective switchgear terminals.

Guaranteed power consumption of the yard conveyor(s) shall be measured during flow path
capacity test in stacking mode whereas for balance equipment, (balance conveyors and S/R
machine) the power consumption shall be measured during the capacity test of reclaim flow
path with boom of Stacker/Reclaimer at lowest angle. Lighting, A/C & ventilation loads on the
Stacker reclaimer shall not be considered for guarantee.

iii) Time Duration

Power Consumption measurement shall be done only for 30 minutes after the
conveyor flow rate stabilizes at the guaranteed capacity. However, for Stacker
Reclaimers, the average power consumption shall be measured for entire duration of
reclaim flow path capacity test.

iv) Meters

Ammeter/Voltmeter readings shall be noted from the meters mounted on the control
desk / LT switchgear / HT switchgear or if necessary by means of clamp type meters.

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For power measurement, two-wattmeter method / one wattmeter method (2 or 3

elements) shall be used. Power measurement shall be taken after stable condition is
achieved.

Watt meters shall have a min. accuracy class of ± 1%. Energy meter shall be of min ±
2%. CTs & VTs shall have accuracy of ± 1%. All meter readings shall be recorded. No
corrective allowance shall be allowed over the measured values.

The details of wattmeter and energy meter along with their calibration certificate shall
be furnished to L&T Power Ltd before start of Tests. These measuring instruments
shall be calibrated from Govt. approved Test Houses.
Calibration certificates of all instruments must not be more than one year prior to test date.
Seals of instruments shall be opened at site in presence of Engineer in-charge. Zero error
shall be checked before conducting the PG test.

2.02.03 GENERAL
(a.) Test Duration

i) Normal duration of the above capacity tests shall be FOUR hours. However, minimum
ONE (1) hour continuous & steady operation shall be required to establish guaranteed
capacities.

ii) In case of any minor interruption due to operation of electrical protection as well as
stoppage due to safety reasons, the duration of test shall be extended by time lost in such
interruptions. In case of exceptionally longer interruptions calling for remobilization and re-
preparations of plant, the implications shall have to be mutually discussed and agreed upon.

(b.) Weighing Scales

i) For measurement of flow capacity of a stream and individual equipment, weighing scales
installed in the system shall be used.

ii) Belt weigher mounted on the luffable boom of Stacker/reclaimer shall not be used for this
purpose.

iii) Readings for flow rate capacity test shall be taken at intervals of every 3 minutes.

iv) Belt weighers accuracy as demonstrated / observed jointly before the guarantee testing may
be considered for allowing correction factor over the recorded flow capacity reading.

(c.) The observations of guarantee tests of various streams / equipment shall be recorded in the
format Appendix- III.

2.03.00 Noise Levels

2.03.01 Noise level measurement, for conformance to specified levels, to be done around the following
equipment / areas:

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(a) Conveyor Discharge Terminal (including discharge chute, gearbox, coupling & motor)

(b) Coal discharge chutes on intermediate floors in possible impact zones.

(c) Ventilation fans

(d) Water supply and dust suppression pumps.

(e) Coal Crushers

(f) Apron Feeders

2.03.02 Noise level measurement shall be done around the specified equipment location in the following
manner.

(a) The measurement shall be carried out with a calibrated integrating sound level meter
meeting the requirements of IEC-651 or BS-5969 or IS: 9779.

(b) Sound pressure level shall be measured all around the equipment at a distance of 1 m from
vertical projected plan of the equipment as a whole (this shall include coupling, gearbox,
motor etc.) at a height of 1.5 m from floor level. Microphone positions shall be at horizontal
separations of not more than 1.5 m around the equipment.

(c) The measurement shall be done with slow or impulse response, as the case may be on the A-
weighing scale. The average of the A-weighted sound pressure level measurements
expressed in decibels to a reference of 0.0002 micro bars shall not exceed the guaranteed
value indicated in the specification.

(d) The tests shall be carried out with the equipment operating at near rated speed & load
correction for background noise will be considered in line with IS: 4758. Noise level
measurement shall be recorded as per format at appendix VI.

2.04.00 POWER CONSUMPTION

1. Flow Path I KW

Crushed Coal Stockpile#1 to Boiler Bunker 1119KW

2. Flow Path 2

Wagon Tippler to Crushed Coal Stockpiles 1919KW

3. Flow Path 3

Wagon tippler to Crushed Coal Stockpile#2 2284 KW

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APPENDIX – I

GENERAL

PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY GMR ENERGY

1. Availability of adequate and uninterrupted supply of coal.

Specification of coal as per NIT and as observed during the test shall be recorded as per attached
format (Appendix-IA)

2. Sufficiently empty bunkers to facilitate continuous tripper dumping of coal during the test.
Sufficient space in Stack yard towards drive end of yard conveyor during stacking. Sufficient
heap of coal towards tail end of yard conveyor during reclaiming of coal.

3. Uninterrupted power supply within specified parameters for the duration of the test.

4. Adequate and uninterrupted water supply

5. Plant communication system

6. Proper lubrication and oil level of all equipment

7. Cleanliness of plant and removal of coal spillage at the start and during tests.

8. Power supply voltage and frequency shall be as per technical specifications.

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APPENDIX – IA

COAL PARAMETERS

Project:
Package:
Date:

S. Parameter As Specified As Observed During The Test

No
1 Size
2 HGI
3 Moisture
4 Shale & sand stone
Content

GMR Energy Ltd L&T BMH

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APPENDIX – II

GENERAL

PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY L&T

1. Deputation of team to site to associate with the Guarantee tests.

2. Calibration of belt Weigher scales and accuracy of same to be demonstrated to GMR.

3. Arrangement of wattmeters / energymeters calibrated and sealed from approved Govt. test houses or
GMR site laboratory or government accredited Laboratory. Arrangement of any other instrument/
accessory for the test.

4. Proper adjustment of skirt boards and belt cleaners prior to the start of tests.

5. Arrangement of calibrated equipment for measurement of vibration & noise levels.

6. Protection Relays setting of LT/HT switchgears and all motor feeders shall be checked.

7. Protection relays setting of LT/HT switchgears and all motors / transformer feeders to be checked

8. Belt protection switches, local stop push button, hooters, brakes / rail clamps in working order.

9. Free rotation of idlers and pulleys.

10. Sufficient illumination.

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APPENDIX – III

FLOW PATH CAPACITY TEST

Project:

Package:

Date:

1. Composition of Stream
i) Conveyor Nos.
ii) Reversible Stacker / Reclaimer
iii) Travelling Tripper Nos.
iv) Dust suppression pumps, service water pumps, Ventilation fan drive.
v) ……………………………
2. Location of Belt Weigher (s)
3. Plant Started at (Time) :
4. Material Started Flow over Belt Weigher (Time):
5. Test Period Completed (Time) :

6. Readings Taken at three (3) minutes intervals :

Sl. No Time Flow Rate Totalizer

Total Plant Run Time: Average Flow Rate:

GMR Energy Ltd L&T BMH

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APPENDIX – IV

POWER MEASUREMENT

Project:

Package:

Date:

1. Equipment / Stream Composition :

2. Motor Description :
3. Sr. No. of meters used :
4. Date of Calibration of Instrument and Name of Test House :
5. Multiplying Factor (M.F.) of the Wattmeter :
6. Wattmeter Readings (to be taken at 1 minute intervals) :

KW Reading

M.F. Total KW
Measureme Startin Voltage Current
(W1+W2) Remarks
SLNO. nt Terminal g Time (Volts) (Amp)
x MF
Location
W1 / W2 M.F
 
                 
               
               
               
               
               
               
               
               
               
               
               
               
               
               

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7. Energy meter Readings

S.no Time Remarks

Energy meter Equipment
Equipment Duration
Readings kw (R2-
kwHr R1)/(t2-t1)
Initial Final Initial Final  
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               

* Reason and duration for system trip / stop may be recorded in remarks column.

GMR Energy Ltd L&T BMH

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APPENDIX – V

PG TEST PROFORMA

VIBRATION LEVEL MEASUREMENTS

Project :
Package :
Date :
Time :

Details of Vibration Level meter:

1. Make:
2. Model & SI No:
3. Date of Calibration with name of Test House

Vibration level Amplitude / Velocity

Sl. Equipment Pick Point
No. Horizontal Vertical Axial
Micron/ Micron/ Micron/
mm/sec mm/Sec mm/sec

Readings shall be taken at all the bearings of motor, gear box and driven equipment. In case of conveyor
galleries, vibrations shall be measured at min. three locations, at midpoint of stringer between two short
supports.

GMR Energy Ltd L&T BMH

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APPENDIX – VI

PG TEST PROFARMA

NOISE LEVEL MEASUREMENTS

Project :
Package :
Date :

Details of Sound Level meter:

1. Make :
2. Model :
3. Date of Calibration with name of Test House :

S. Equipment with Equipment Measurements Point Sound Level Remarks

No location Load/ capacity No. dBA

* For each equipment location a projected plan diagram shall be made and the location of
measurement point shall be identified.

GMR Energy Ltd L&T BMH

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APPENDIX-VII

PROFORMA FOR POWER MEASUREMENT OF REVERSIBLE STACKER/RECLAIMER

1. Stream composition :

2. Description of following motors.

a. Boom Conveyor

b. Bucket Wheel

c. Long Travel

d. Main Hydraulic pump.

3. Sr. No. of energy meter used

4. Date of calibration of instrument and name of test house.

5. Multiplying factor of energy meter

6. Energy readings (to be taken at H.T SWGR. FDR of S/R incomer of MCC on S/R

Sl.No Equipment Time Duration Energy meter Equipment Remarks

Readings KW
KWHR
Initial Final Initial Final (R2-R1)/(T2-T1)
T1 T2 R1 R2

Reason and duration for trip/stop may be recorded in remarks

GMR Energy Ltd L&T BMH

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