UPS-FRM-002

UPS Operator Competency Assessment

Operator: Operator Signature: Date:

Assessor: Assessor Signature: Date:

Contents
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Siemens Nomenclature P&ID Symbols Gas Turbine General Generator Generator Cooling System Lube Oil System Hydraulic Oil System Fuel Gas System Air Intake System Blow Off System Bearings Water Injection System Compressor Wash System Gas Yard Electrical Distribution System The Governor SFC and SEE T3000, SGCs, SLCs, Logic and the DCS General Operator Duties GCNF Turbine Start-up, Operation and Shutdown Turbine Trip 4 6 9 12 13 14 16 18 21 22 24 25 26 27 28 31 32 33 35 36 37 38

Page 2 of 38

Information
This assessment shall be completed by new operators employed at the Uranquinty Power Station. There is no set time period for completion of the assessment, however it is envisaged that it would be completed within three months from commencement of employment. Answers can be obtained from Original Equipment Manufacturer manuals, experience, through discussion with experienced operators and inspection of the plant. The assessment will be marked by a Subject Matter Expert. A pass mark of 85% is required.

Page 3 of 38

Section 1: Systems Theory

1
Q 1.1

Siemens Nomenclature
What is the KKS system and what is its purpose? Marks: 2

Q 1.2

What is 13MBV21AP001. Break down the tag number using the KKS system.

Marks: 2

Q 1.3

Write down the system identification code for each of the following systems: KKS Identification Code

Marks: 16

System Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 GT Main Machine Set Lube Oil Gas Supply Fuel Gas Hydraulic Oil Demin Pag Air Intake Combustion Chamber Exhaust Diffuser Bearings Generator Generator Cooling Buildings Turbine Hall Ventilation

Q 1.4

What do the following equipment identification codes represent? Description

Marks: 10

Equipment Identification Code 1 2 3 4 5 6 7 8 AP AA AT BB CP CT CH GA

Page 4 of 38

9 10

GT XQ

Q 1.5

What do the following equipment serial number ranges for valves generally represent? Description

Marks: 7

Equipment Serial Number 1 2 3 4 5 6 7 001 - 199 001 - 050 181 - 199 051 - 090 301 399 401 - 499 501 599

Q 1.6

What do the equipment serial number ranges for measuring instruments generally represent? Description

Marks: 5

Equipment Serial Number 1 2 3 4 5 001 - 199 001 - 099 101 - 199 401 - 499 501 599

Page 5 of 38

2
Q 2.1

P&ID Symbols
What do the following P&ID symbols represent? Note that the meaning of the symbols may vary depending on the manufacturer. Symbol Description Marks: 16

10

11

12

13

Page 6 of 38

14

15

16

Q 2.2

Draw the P&ID symbol to match the description. Note that the meaning of the symbols may vary depending on the manufacturer. Symbol Description

Marks: 20

Combustion chamber hybrid burner / flame

Compressor

Filter

Check valve

Generator

Solenoid coil

Spring

Flow restrictor / orifice

Flexible hose

10

Shut off valve

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11

Shut off valve with adjustment/control

12

Check valve

13

Diaphragm-actuated shutoff valve

14

Piston-actuated shutoff valve

15

Hand actuated shutoff valve

16

Silencer

17

Piping / flow line

18

Interconnection of piping lines with fittings

19

Air

20

Butterfly valve

Page 8 of 38

3
Q 3.1

Gas Turbine General

Identify the major components of the gas turbine. Component Marks: 9

1 2 3 4 5 6 7 8 9

Q 3.2

Briefly describe how the V94.2 gas turbines work.

Marks: 3

Q 3.3

How is the mechanical torque provided by the turbine converted into electrical energy?

Marks: 1

Q 3.4

What is the shaft limit of the turbine?

Marks: 1

Q 3.5

What effect do the pressure, temperature and humidity of the ambient air have on the output of the gas turbine?

Marks: 1

Q 3.6

Which manual does the below cutaway of the gas turbine come from?

Marks: 1

Q 3.7

What is the purpose of the rotor? Describe its general construction.

Marks: 1

Page 9 of 38

Q 3.8

What is a Hirth serration? Draw a section of a Hirth serration.

Marks: 1

Q 3.9

Identify areas 1 6 of the compressor rotor blades. Identify on the below diagram the location of the Hirth serration. Component 1 2 3 4 5 6

Marks: 3

Q 3.10

What is the purpose of the thermal barrier coating on the turbine blades and vanes?

Marks: 1

Q 3.11

Using the schematic of one of the silo type combustion chambers, indicate the general flow of air, fuel and combustion gasses using the colours indicated below.

Marks: 1

Compressor discharge air Fuel Combustion gasses

Q 3.12

Identify areas A D of the turbine blade, as indicated below. Description

Marks: 4

Page 10 of 38

A B C D

Q 3.13

Discuss how the stator vanes and rotor blades of the turbine section are cooled.

Marks: 1

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4
Q 4.1

Generator
What is the function of the generator? Marks: 1

Q 4.2

Using the diagram below, describe the fundamental principle of how the generator works. [The different coloured circles represent the three different phases].

Marks: 1

Q 4.3

For the schematic of a stator slot, identify components 1-8. Description 1 2 3 4 5 6 7 8

Marks: 8

Source of answer:

Page 12 of 38

5
Q 5.1

Generator Cooling System

Why does the generator need to be cooled? Marks: 1

Q 5.2

Describe how the generator is cooled.

Marks: 2

Q 5.3

Describe how the fin fan cooling fans are controlled.

Marks: 5

Q 5.4

How long does the generator cooling system remain on for after the turbine is shutdown?

Marks: 1

Q 5.5

Describe the flow of air through the generator using the diagram in Q 5.7 as an aid.

Marks: 3

Q 5.6

How is the excitation equipment cooled?

Marks: 1

Q 5.7

Identify the components A and B in the diagram below. A B

Marks: 2

Page 13 of 38

6
Q 6.1

Lube Oil System

What is the purpose of the lube oil system and why is it necessary for these turbines? Marks: 2

Q 6.2

Draw a top cross-sectional view of the lube oil tank and describe its design. Why is the capacity of the lube oil tank so large?

Marks: 3

Q 6.3

Describe how the turning gear system works and why it is necessary.

Marks: 2

Q 6.4

Explain what would happen to the shaft if the turbine shut down from base load operation without going on turning gear.

Marks: 1

Q 6.5

What is lift oil and when is it used?

Marks: 2

Q 6.6

Explain how the lube oil system works when the turbine is generating.

Marks: 1

Q 6.7

What is the purpose of the oil mist eliminator?

Marks: 1

Q 6.8

What is the purpose of MBV21AP003 and where does its electrical supply come from?

Marks: 1

Q 6.9

What is the temperature of the lube oil maintained at? Describe the lube oil heating and cooling system and how it maintains this temperature.

Marks: 1

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Q 6.10

Identify the components listed A-J in the diagram below.

Marks: 10

KKS A B C D E F G H I J

Description

Page 15 of 38

7
Q 7.1

Hydraulic Oil System

What is the main purpose of the hydraulic oil system? Marks: 2

Q 7.2

Which components in the plant are controlled by hydraulic oil?

Marks: 4

Q 7.3

At what pressure does the system supply hydraulic oil to these components?

Marks: 1

Q 7.4

At what temperature is the air-cooler MBX06AH001 energised and de-energised?

Marks: 1

Q 7.5

Which manual can the hydraulic oil P&ID be found in? What page is it found on?

Marks: 2

Q 7.6

What is the purpose of MBX04BB001 and MBX04BB002?

Marks: 1

Page 16 of 38

Q 7.7

Explain what is happening in the trend below in regards to the hydraulic oil system:

Marks: 1

Q 7.8

Label the main components of the hydraulic oil system as indicated in the picture below:

Marks: 1

Description A B C D E Page 17 of 38

8
Q 8.1

Fuel Gas System

What is the fuel gas system? Marks: 1

Q 8.2

Using the screen shot of the fuel gas control screen, describe its major components.

Marks: 1

KKS 1 2 3 4 5 6 7 8 9 10 11

Component

Q 8.3

Describe the fuel gas system valve line up steps when the turbine is starting up. Develop a trend to substantiate your answer.

Marks: 11

Page 18 of 38

Speed [Hz] 1 2 3 4

Step Description

5 6 7

9 10

Q 8.4

What is the purpose of the last chance strainer MBP12AT001?

Marks: 1

Page 19 of 38

Q 8.5

How long does it take for the natural gas ESV MBP13AA051 close? What system enables this valve to close so quickly?

Marks: 1

Q 8.6

Indicate on the diagram of the fuel gas burner (hybrid burner) the flow path of ignition, diffusion, premix, pilot gas and air using the colours below.

Marks: 5

Ignition Diffusion Premix Pilot Air

Q 8.7

Describe the shut down procedure for the fuel gas system.

Marks: 11

Q 8.8

What could cause a rapid changeover from premix to diffusion operation?

Marks: 4

Q 8.9

How does the fuel gas system react in the event of a load rejection trip?

Marks: 2

Page 20 of 38

9
Q 9.1

Air Intake System

What is the purpose of the air intake system Marks: 1

Q 9.2

Name, and describe the purpose of the components of the air intake system.

Marks: 10

Q 9.3

What is the purpose of the variable inlet guide vanes?

Marks: 1

Q 9.4

By tracing the logic, what are the differential pressure alarm set points when the IGVs are 100% open? KKS DP Alarm Set Point with IGVs 100% Open [mbar

Marks: 1

Component Name Pre filter Fine filter Coalescer Overall Overall DP trip

Q 9.5

Describe the consequences of having excessive differential pressure across the air intake?

Marks: 1

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10
Q 10.1

Blow Off System

How many blow off valves are there and from which stages of the compressor do they take air? Marks: 1

Q 10.2

What is compressor surge and how does it relate to the blow off system?

Marks: 1

Q 10.3

In which manual can the functional description be found?

Marks: 1

Q 10.4

How are the blow off valves actuated?

Marks: 1

Page 22 of 38

Q 10.5

Print a trend that includes the blow off valves, MW and speed and use this to explain the operation of the blow off valves.

Marks: 3

Page 23 of 38

11
Q 11.1

Bearings
What is the purpose of the bearings? Marks: 1

Q 11.2

What is the bearing metal temperature limit? What temperature setting will cause a turbine trip?

Marks: 1

Q 11.3

What could cause a fire at the bearings?

Marks: 1

Q 11.4

How is temperature measured at the bearings?

Marks: 1

Page 24 of 38

12
Q 12.1

Water Injection System

What is the water injection system, what is it normally referred to on site and what does this acronym mean? Why is it used? Are there penalties using this system? Marks: 1

Q 12.2

When is PAG used?

Marks: 1

Q 12.3

Give a brief description of how PAG works.

Marks: 1

Q 12.4

Is PAG an automatic system?

Marks: 1

Page 25 of 38

13
Q 13.1

Compressor Wash System

What is the purpose of the compressor wash system? Marks: 1

Q 13.2

What is the effect of any residue that may be present on the compressor blades?

Marks: 1

Q 13.3

Explain how to do a compressor wash.

Marks: 1

Q 13.4

Give the file path for the compressor wash procedure.

Marks: 1

Page 26 of 38

14
Q 14.1

Gas Yard
What is a Coalescer and what is its function in the Gas Yard? Marks: 1

Q 14.2

Explain the purpose of the boiler gas supply heating skid.

Marks: 1

Q 14.3

What do the boilers do?

Marks: 1

Q 14.4

Explain why it is necessary to heat the gas when it enters site. How is the gas heated?

Marks: 3

Page 27 of 38

15
Q 15.1

Electrical Distribution System

The output voltage of the generator is 15.75 kV. What voltage is it stepped up to for distribution to the grid? Marks: 1

Q 15.2

What three voltages is the 15.75 kV of the output stepped down to for distribution and use around site? What do the three voltages that are transformed from the 15.75 kV supply?

Marks: 3

Q 15.3 Photo

What are the photos of below? Description

Marks: 1

Q 15.4

What is the purpose of the battery system?

Marks: 1

Page 28 of 38

Q 15.5

What equipment can the batteries supply power to? KKS Description

Marks: 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Q 15.6

What equipment does the BME bus supply? KKS Description

Marks: 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Q 15.7

What is the purpose of the two diesel generators? What are their KKS numbers?

Marks: 1

Page 29 of 38

Q 15.8

When do the diesel generators operate? What equipment do they supply?

Marks: 1

Page 30 of 38

16
Q 16.1

The Governor
What is the Governor responsible for? Marks: 8

Q 16.2

List the slave controllers that are incorporated into the Governor.

Marks: 8

Q 16.3

What manual is the Governor described in?

Marks: 1

Q 16.4

Describe how the speed of the GT is controlled.

Marks: 1

Q 16.5

Discuss frequency stabilisation.

Marks: 1

Q 16.6

What is the Corrected Turbine Outlet Temperature Controller?

Marks: 1

Page 31 of 38

17
Q 17.1

SFC and SEE

What is the SFC and SEE? Marks: 1

Q 17.2

At what step of the GT SGC is the SFC turned on? What does the SFC controller do when it is turned on?

Marks: 1

Q 17.3

When does the SFC automatically turn off? What happens when the SFC is commanded off?

Marks: 1

Q 17.4

What can the excitation current influence?

Marks: 1

Q 17.5

How many SFCs are there at UPS? How are they connected?

Marks: 1

Q 17.6 Photo

What is the picture of below? Description

Marks: 1

Page 32 of 38

18
Q 18.1

T3000, SGCs, SLCs, Logic and the DCS

What is the function of the T3000 control system? Marks: 1

Q 18.2

Give two ways you can arrive at the logic through the DCS.

Marks: 1

Q 18.3

How can you tell if an item is archived for trending?

Marks: 1

Q 18.4

How would you create an alarm sequence report?

Marks: 1

Page 33 of 38

Q 18.5 Column

Describe the field name for each of the columns in the operations ASD. Description

Marks: 1

Q 18.6 Symbol

What do each of the below icons on the DCS represent? Description

Marks: 1

Q 18.7

How do you determine what function a logic block is performing if you cannot determine this from inspection of the block?

Marks: 1

Q 18.8

What is an embedded logic diagram? How do you look at an embedded logic diagram?

Marks: 1

Page 34 of 38

Section 2:
19
Q 19.1

Operations
Marks: 1

General Operator Duties

What are your Health, Safety and Environmental (HSE) duties?

Q 19.2

What is the purpose of completing a walk down? Whose responsibility is it to complete a walkdown?

Marks: 1

Q 19.3

Describe the tasks that the first person on site must complete.

Marks: 1

Q 19.4

Describe the operators duties when he leaves site.

Marks: 1

Q 19.5

What must you do if you receive a phone call from the Traders or make a phone call to the Traders?

Marks: 1

Q 19.6

Discuss what you should do in the event an alarm or warning comes in on the Alarm Sequence Display (ASD).

Marks: 1

Page 35 of 38

20
Q 20.1

GCNF
What is a GCNF and what does GCNF stand for? Marks: 1

Q 20.2

Describe who must complete the GCNFs and who the GCNFs must be distributed to. What is the procedure for writing a GCNF.*

Marks: 1

Q 20.3

Discuss how the GCNF form is revised.*

Marks: 1

Page 36 of 38

21
Q 21.1

Turbine Start-up, Operation and Shutdown

Explain the steps to turn the boilers on when they are initially shutdown. Marks: 5

Q 21.2

What order of lights should you look for when the boilers are starting up from shutdown?

Marks: 4

Q 21.3

What are the temperature set points that are used for the three boilers? Boiler 1 Boiler 2 Boiler 3

Marks: 3

Control Set Point C: Cut-out Temperature C:

Q 21.4

Describe what you must do on start up of the turbine.

Marks: 1

Q 21.5

Describe your duties during turbine operation.

Marks: 1

Q 21.6

Describe what you must do on shutdown of the turbine.

Marks: 1

Q 21.7

When is remote operations enabled?

Marks: 1

Page 37 of 38

22
Q 22.1

Turbine Trip
What must you do in the event of a turbine trip? Marks: 5

Page 38 of 38