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Boiler Commissioning

The document provides information on commissioning a boiler and its auxiliaries. It discusses pre-commissioning checks that include inspection, testing, and trial runs of equipment. It also details the hydraulic test of the boiler, which pressures all drainable and non-drainable parts to test for leaks. Additional steps covered include chemical cleaning, gas tightness testing using smoke generators, safety valve setting calibration, and commissioning other auxiliary equipment and systems.

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gaurav tiwari
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© © All Rights Reserved
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Available Formats
Download as PPT, PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
314 views80 pages

Boiler Commissioning

The document provides information on commissioning a boiler and its auxiliaries. It discusses pre-commissioning checks that include inspection, testing, and trial runs of equipment. It also details the hydraulic test of the boiler, which pressures all drainable and non-drainable parts to test for leaks. Additional steps covered include chemical cleaning, gas tightness testing using smoke generators, safety valve setting calibration, and commissioning other auxiliary equipment and systems.

Uploaded by

gaurav tiwari
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 80

BOILER

COMMISSIONING
June 27, 2015

PMI Revision 00

BOILER AND AUX. COMMISSIONING

COMMISSIONING :It is the later stage of


erection and starting stage of operation.
It includes 14 days of continuous
operation with 72 hrs of full load operation.

June 27, 2015

PMI Revision 00

INTRODUCTION TO COMMISSIONING
Commissioning Activities before taking over a
plant.
Purpose
To check that plant is supplied as per design
Quality of erection and commissioning
Plant operates reliably, safety & design
performance.
Finding out reason for any failure to achieve the
design performance.
June 27, 2015

PMI Revision 00

INTRODUCTION TO COMMISSIONING
Organization

Steering committee Policy and priorites.


Ensures adequate resource. Approval of
documents. Headed by G.M.
Commissioning panel Control & progress of
day to day activities. Coordination between
Test teams and Working groups. Erection &
O&M dept.
Working groups Looks after requirement of
Test team.
Test Team Conducting testing &
commissioning.
June 27, 2015

PMI Revision 00

INTRODUCTION TO COMMISSIONING

Documentation
1. Papers of principle Prepared jointly by
Erection and corporate O.S.

To set out principles & objectives


Established design data to compare
plant.
Define documentation requirement

June 27, 2015

PMI Revision 00

INTRODUCTION TO COMMISSIONING

Documentation
2. Testing & commissioning Schedule

To meet the requirement of the paper of


principle
Plant under cover
Detail test method & programme
Safety
Emergencies
Individual responsibility
Results
June 27, 2015

PMI Revision 00

INTRODUCTION TO COMMISSIONING

Documentation
3. Standard checklist

Ensuring completion of erection


Limited extent operation
Test conductance in consistent
manner
Instrument providing Schedule with
range & resolution and calibration
validation.
June 27, 2015

PMI Revision 00

INTRODUCTION TO COMMISSIONING

Documentation
4. Design change notification
5. Test reports
Recording of result
Omission report
Analysis
6. Safety procedure
7. Plant certification
Safety clearance certificate
Record of initial operation
Clearance for station operation certificate
Initial taking over certificate
Final internal contract clearance completion of guarantee
period
8. Plant completion report. PG test evaluation and acceptance

June 27, 2015

PMI Revision 00

--------------------------------------------------------------------------------------------------------------------MECHANICAL
-------------------------------------------------------------------------------------------------------------------STATION
STANDARD CHECK LIST
SHEET 1 OF2
--------------------------------------------------------------------------------------------------------------------PLANT ITEM
PIPEWORK-CONSTANT LOAD SUPPORT
--------------------------------------------------------------------------------------------------------------------PLANT NOMENCLATURE
SYSTEM ----------------------------------------------------MANUFACTURER--------------------------- SRL. NO.--------------------------------------------------LOCATION----------------------------------------------------------------------------------------------------NO
ACTIVITY
WITNESSED
Date
-------------------------NTPC
CONTR
1.General conditions satisfy the Site standing Instructions as listed In the Plant Item
Commissioning Essential Pre requisites(SCL MS1/1)
2.The name plate legend agrees with the approved NTPC plant Nomenclature is clearly
visible securely fixed, durable and correlates with remote labels.
3.The installation is complete and correct in accordance with the latest drawing and
specification and support attachments to building Steel work and pipework are secure
and satisfactory.
4.Access for adjustments maintenance and repairs is a satisfactory,
5.Check that support-setting details can be easily read.
REMARKS
--------------------------------------------------------------------------------------------------------------------SCL REF: M/4/6

June 27, 2015

PMI Revision 00

------------------------------------------------------------------------------------------------------------------CONTROL & INSTRUMENTATION


--------------------------------------------------------------------------------------------------------------------STATION
TEST PROCEDURE
SHEET 1 OF 2
--------------------------------------------------------------------------------------------------------------------- INSTRUMENTS:
PRESSURE GUAGE
TP REF: 1.5.1.
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------NTPC TAG NO
UNIT
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------No.
Activity
Remarks
--------------------------------------------------------------------------------------------------------------------1.Test Equipments Required.
1.1Portable Dead Weight Tester, Comparator. Or other similar sure of the vacuum source.
1.2Standard Test gauge if not using a dead weight tester, other standard pressure vacuum gauge, dependent
on the range of the instrument being tested.
2.Check calibration of the test Equipment.
3.Check the gauge calibration over its entire range 20% steps, increasing and decreasing, Allow for head
correction where necessary, Note the results on Standard Calibration sheet 1.15.1.
4.Recheck the calibration of the test equipment.
5.Acceptable errors for pressure gauges, unless otherwise specified in the contract specification are:Standard of Test gauges +_ 0.25% FSD.
--------------------------------------------------------------------------------------------------------------------DEFECTS & OMISSIONS CONTINUATION OVERLEAF
--------------------------------------------------------------------------------------------------------------------REMARKS
--------------------------------------------------------------------------------------------------------------------- NTPC SIGNATURE
CONTRACTORS SIGNATURE
DATE
---------------------------------------------------------------------------------------------------------------------

June 27, 2015

PMI Revision 00

10

BOILER AND ITS AUXILIARIES

Steps
Pre-commissioning checks
Trial run of equipments
e.g. Fans and APH commissioning
Hydraulic Test
Chemical cleaning
Gas Tightness Test
ESP commng.
Fuel Oil System
Preparation for first light-up
Steam blowing
Safety v/v settings
Other boiler Aux. commissioning

June 27, 2015

PMI Revision 00

11

BOILER AND ITS AUXILIARIES


Pre commissioning checks
Physical inspection
Ensuring tightness
Lubrication check
Setting of relief v/v
Operation test on v/vs and fittings
Insulation test on cable/ motor
Rotation checks
Flushing out the oil system
Trial run of motor with all protection for 8 hrs
Coupling of fan with motor
June 27, 2015

PMI Revision 00

12

BOILER AND ITS AUXILIARIES


Trial run of equipments
Commissioning checks
Checking of IGV/ pitch control mechanism
Operation of lub oil pump system
Operation of Discharge damper
Starting the fan as recommended by mfd.
8 hrs trial run conductance
Logging parameters.

June 27, 2015

PMI Revision 00

13

BOILER AND ITS AUXILIARIES

Pre commissioning checks for boiler


Hydraulic test
For both drainable and non drainable portions
Filled with DM water. Add 10 ppm ammonia and 200 ppm
hydrazine
All drainable and non drainable parts to be filled through their
bottom drains.
High pressure positive displacement pump is used.
Test pressure as per IBR recommendation.
Pressure should be raised gradually.
After pressurization hold and inspect.
Wet preservation done after draining

June 27, 2015

PMI Revision 00

14

June 27, 2015

PMI Revision 00

15

BOILER HYDRAULIC TEST

June 27, 2015

PMI Revision 00

16

CHEMICALS REQUIREMENT

June 27, 2015

PMI Revision 00

17

June 27, 2015

PMI Revision 00

18

June 27, 2015

PMI Revision 00

19

June 27, 2015

PMI Revision 00

20

June 27, 2015

PMI Revision 00

21

BOILER AND ITS AUXILIARIES

Pre commissioning checks for boiler


Gas tightness check
Through smoke generator. 24 MKS,40 IBS wt.
from defance store.
Run FD and ID.

June 27, 2015

PMI Revision 00

22

June 27, 2015

PMI Revision 00

23

June 27, 2015

PMI Revision 00

24

AIR AND GAS TIGHTNESS TEST OF


FURNACE AND DUCTS

STAGE 1 : FD fan to air inlet damper of APH 300


mmWC
STAGE II : APH inlet damper to wind box. - 300
mmWC
STAGE III : Wind box to APH gas O/L damper. - 75
mmWC
STAGE IV : APH O/L damper to ESP I/L gate. - 300
mmWC
June 27, 2015

PMI Revision 00

25

AIR AND GAS TIGHTNESS TEST OF


FURNACE AND DUCTS
STAGE V : ESP O/L damper to ID fan I/L damper - 300
mmWC
STAGE VI : ID fan I/L damper to stack. kerosene test.
STAGE VII : PA fan to PAPH I/L damper. (SCAPH bypass,
cold air duct and seal air pipes. - 500 mmWC
STAGE VIII : PAPH air I./L to hot air gates 500 mmWC
ESP is tested by air in leak test.
June 27, 2015

PMI Revision 00

26

AIR AND GAS TIGHTNESS TEST OF


FURNACE AND DUCTS
ALL DAMPERS ARE TO BE SEALED.
NMEJs ARE TO BE ERECTED.
NO INSULATION OVER THE DUCT.
ALL AIR LEAKS ARE TO BE CHECKED BY SOAP SOLUTION.
BAH GATES AND SEAL TROUGH ARE TO BE CLOSED.
MANOMETERS ARE TO BE PROVIDED TO NOTE THE PRESSURE.

June 27, 2015

PMI Revision 00

27

PROTOCOL ON SMOKE GENERATOR TEST


OF THE BOILER
Name of the site:
Unit NO:
The smoke generator test was carried out on the procedure to detect and rectify the
leaking portions in the systems. The leakage found has been rectified. Details of the No.
of smoke generators used indifferent sections are given below.
--------------------------------------------------------------------------------------------------------------------Date
Section
No. Of Smoke
Remarks
Generators
used
--------------------------------------------------------------------------------------------------------------------Cold Air duct
Hot Air
Second Pass
Furnace
-------------------------------------------------------------------------------------------------------------------EP LEFT
EP RIGHT
--------------------------------------------------------------------------------------------------------------------Leakages found during the test were rectified and wherever necessary a repeat test was
done.
CUSTOMER
CONSULTNT

June 27, 2015

PMI Revision 00

28

BOILER AND ITS AUXILIARIES


ESP commissioning
Physical inspection.
Electrical inspection
Gas distribution test
Air load test

June 27, 2015

PMI Revision 00

29

BOILER AND ITS AUXILIARIES


Fuel oil system
Physical inspection.
Flushing of lines.
Trial of pumps.
Ignitor and burner housing check.

June 27, 2015

PMI Revision 00

30

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)
Alkali boil-out
Purpose: Chemical cleaning of boiler water & steam
system to remove loose foreign material, oil, grease etc.
Water Washing Temporary water filled arrangement. It
continues till conductivity of inlet/ outlet water equals.
Process continued nos. of time till conductivity of washing
water matches with fresh filtered water.

June 27, 2015

PMI Revision 00

31

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)
Alkali boil-out
Alkali boil out Fill water with DM water. Add Trisodium phosphate
(1000 PPM 0.1%), Do Decca Hydrate & Hydrazine Hydrate (200
PPM 0.02 %)
Filling upto 180 mm.
Boiler light up with AB elevation
Pressure raised to 40 Kg/ Cm2.
Hourly blow down given to remove impurities and feeding maintain to
keep drum level.
Oil gun to cut out during blowing
Boiler expansion noted
At the end boiler will be boxed up and hot draining done when pr.is
1.5 Kg./Cm2.

June 27, 2015

PMI Revision 00

32

COMMISSIONING PROTOCOL FOR ALKALI BOIL OUT


PROJECT------------------------------------------- CONTRACT NO ---------------------------------UNIT NO ------------------------------ RATING ------------------------ MW. CUSTOMER---Alkali Boil Out Boiler was carried out from------------------------------------------------------(date)
To-------------------------------------------(Date).
The following chemicals were changed:
TRISODIUM PHOSPHATE --------- Kgs (--------- ppm).
The boil out was carried out at 40-kg/cm2 pressures for a period of ----------------------------Hence and the process was declared completed-------------------------------------------- -------at
----------------------------------- Hrs----------------------------(date).
The end point values are as follows:
------------------------------------------------Ph
po4 ppm Oil ppm
------------------------------------------------------------------------------------------------------------REMARKS:
------------------------------------------------------------------------------------------------------------Manufacturer
Customer Engineer

June 27, 2015

PMI Revision 00

33

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)
Acid cleaning

Covering steam and water ckt., economiser, waterwall,


Boiler Drum excluding super heaters, reheater &
associated piping.
Stage I Acid washing
II DM water rinsing
III Citric acid water rinsing
IV DM water rising
V Neutralising with sodium carbonate.
VI Passivation 1st stage.
VII Inspection
VIII Passivation 2nd stage.

June 27, 2015

PMI Revision 00

34

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)

Acid cleaning

HCL 4-6 % conc.


Ammonia Bifluoride 1%
Rodine 213 special 0.1 % inhibitor.
Lime
Nitrogen Gas capping arrangement.
Removal of Drum internals
Down comer fitted with orifice. Sup heater steam
opening at drum to be plugged by rubber stamp.
S/H to be kept pressurised at 5 Kg/Cm2 with
hydrazine.
June 27, 2015

PMI Revision 00

35

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)
Acid cleaning procedure

Fill boiler with water and a circulation flow of 400 t/Hr is


maintained.
Heat water to 65 deg cen. With steam.
Inhibitor charged and half quantity of ammonia bifluoride.
When the above mixture get dissolved, start acid dosing.
Concentration should not exceed 6 %.
Temp. is maintained below 70 Deg.
HCL and Iron Conc. Intially goes high then comes down
and became steady.
Constant value of HCL and iron conc. Denote completion
of acid washing.
Cleaning soln. drained through neutralising pit.

June 27, 2015

PMI Revision 00

36

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)
Rinsing with water.
System filled with water
Temp. raised to 65 Deg.
Water circulation continue.
Water is dump under nitrogen capping.

June 27, 2015

PMI Revision 00

37

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)
Citric acid rinsing.
System filled with water
Temp. raised to 65 Deg.
Citric acid 0.2 % by weight.
Water is recirculated
When inlet outlet sample matches then
declare over
Water is dump under nitrogen capping.
June 27, 2015

PMI Revision 00

38

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)
Neutralisation.
System filled with water
Temp. raised to 80 Deg.
Sodium Carbonate 1 %..
Water is recirculated
When inlet outlet sample matches then
declare over
Water is dump under nitrogen capping.
June 27, 2015

PMI Revision 00

39

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)

Passivation 1st stage.

Purpose building uniform layer of Magnetite on


bare surface obtained after acid cleaning.
System filled with water
Temp. raised to 85 Deg.
300 ppm Hydrazine (9.6 pH)
Water is recirculated
Maintain hydrazine concentration to 150 ppm.
When inlet outlet sample matches then declare over
Water is dump under atmospheric capping.

June 27, 2015

PMI Revision 00

40

BOILER AND ITS AUXILIARIES


(Chemical Cleaning)
Passivation 2nd stage.

Purpose building uniform layer of Magnetite on bare


surface obtained after acid cleaning.
System filled with water
Temp. raised to 85 Deg.
300 ppm Hydrazine (9.6 pH)
Boiler lighted up. 40 Kg pr. Raised. Maintain for 20
Hrs.
Maintain hydrazine concentration to 150 ppm.
Hot drain at 90 deg.
Water is dump under atmospheric capping.

June 27, 2015

PMI Revision 00

41

STEAM BLOWING
OF
BOILER AND
ASSOCIATED STEAM LINE
INCLUDING
AUXILIARY STEAM LINES

June 27, 2015

PMI Revision 00

42

CLICK ON THE STAGE TO SEE THE ANIMATION

THEORY OF STEAM BLOWING


SCHEME OF STEAM BLOWING
STAGE-1 STEAM BLOWING (SH,M.S LINE UP TO ESV)
STAGE-2A STEAM BLOWING (SH,M.S, CRH LINE)
STAGE-2B STEAN BLOWING (SH,MS,HRH&CRH UP TO DESH)
STAGE-3A STEAM BLOWING (SH, MS, CRH, RH, HRH, UP TO IV)
STAGE-3B STEAM BLOWING (SH, MS, CRH, RH, HRH & LPBP )
STAGE-4A STEAM BLOWING (EXTRN TO BFPDT-A, FROM CRH)
STAGE-4B STEAM BLOWING (EXTRN TO BFPDT-B, FROM CRH)
CLICK / ENTER, AFTER EVERY EVENT IN THE SCHEME TO SEE THE
SEQUENCE OF EVENTS

June 27, 2015

PMI Revision 00

43

STEAM BLOWING

BACK TO
INDEX

OBJECTIVE:

PURPOSE OF STEAM BLOWING IS TO REMOVE


SCALES, LOOSE MATERIAL, IRON CUTTINGS etc. THAT MIGHT HAVE
BEEN ENTRAPPED IN S.H, STEAM PIPING, REHEATERS DURING
MANUFACTURE.

TECHNIQUE:

STEAM BLOWING IS CARRIED OUT BY PUFFING


METHOD.THIS TECHNIQUE WILL GIVE A THERMAL SHOCK TO THE
CONTOUR BEING PURGED TO DISLODGE THE SCALES etc. WHICH WILL
SUBSEQUENTLY BE REMOVED BY EXPANDING STEAM.

PROCEDURE:

FOR BLOWING THE STEAM, RAISE THE BOILER


DRUM PRESSURE UPTO 40 TO 50 Ksc; SHUT OFF BOILER FIRING AND
OPEN THE ELECTRICALLY OPERATED TEMPORARY VALVES (EOTVs) /
BOILER M.S. STOP VALVES AS SHOWN IN THE FOLLOWING SCHEMES.
DRUM LEVEL SHOULD BE MAINTAINED AT LOWEST PORT (VISIBLE
LIMIT) BEFORE THE START OF EACH BLOW TO AVOID WATER
DROPLETS CARRYOVER TO THE SATURATED STEAM PIPING.
NUMBER OF BLOWS PER DAY ARE LIMITED TO 8 WITH AN INTERVAL
OF 1 Hrs.FOR COOLING IN ADDITION TO OVER NIGHT COOLING

SCHEME: STEAM BLOWING IS DONE IN


DESCRIBED
June
27, 2015IN THE FOLLOWING
PMISLIDES.
Revision 00

SEVEN STAGES AS

44

STEAM BLOWING SCHEME

EOTV

MS STOP V/V

R
H
O

R
H
I

H
D
R

D
E
S
H

S
H
I
H

BACK TO
INDEX

C
D

ESV

S
H
O
H

M
S
L

H
D
R

D
C
R
H

THRO / BLANK
FLANGE

HOTVs

N
R ESV
V

EOTV

HPBP SPOOL
PIECE 450

HPBP LINE
LPBP V/V

CRH LINE

HRH LINE

--THRO / BLANK FLANGE

-- S.H & MS LINE


-- CRH & HPBP

--TARGET PLATE June 27, 2015


--UN TREATED PIPE

-- R.H & HRH LINE


-- LPBP LINE

-- TEMPORARY PIPING
-- PERMANENT PIPING
-- OPEN INDICATION
-- CLOSE INDICATION

LPBP V/V

TO CONDENSER

HOTV-HAND OPERATED
TEMPORARY VALVE
45
EOTV ELECTRICALLY OPERATED
TEMPORARY VALVE

STAGE-I

EOTV

MS STOP V/V

R
H
O
H
D
R

R
H
I
H
D
R

S
H
I
H

D
E
S
H

BACK TO
INDEX

A
C
D

ESV

S
H
O
H

M
S
L

D
C
R
H

THRO / BLANK
FLANGE

HOTVs

N
R ESV
V

EOTV

HPBP SPOOL
PIECE 450

HPBP LINE
LPBP V/V

CRH LINE

HRH LINE
--THRO / BLANK FLANGE

-- S.H & MS LINE


-- CRH & HPBP

--TARGET PLATE

June
27, 2015
--UN TREATED PIPE

-- R.H & HRH


-- LPBP

PMI

-- TEMPORARY PIPING
-- PERMANENT PIPING

LPBP V/V

TO CONDENSER

STAGE-1
FLANGES
BLOW
OFF
COVERS
"B,"C,"D&"E
V/V OPENED
SUPER
AT 50
MS STOP
STEAM
BLOWING
VALVES
IN
IS
TO BE
-- OPEN
ARE
Ksc
HEATERS
&BLANKED,
CLOSED
& MSUSING
AT
LINE
"A25ISUP
Ksc
TO
OPEN
CARRIED
CONDITION
OUT
EOTVS
Revision
00 PRESSURE
46
-- CLOSE
OPENED
DRUM
ESV

STAGE-IIA

EOTV

MS STOP V/V

R
H
O

R
H
I

H
D
R

S
H
I
H

D
E
S
H

BACK TO
INDEX

A
C
D

ESV

S
H
O
H

M
S
L

H
D
R

THRO / BLANK
FLANGE

C
R
H

HOTVs

N
R ESV
V

EOTV

HPBP SPOOL
PIECE 450

HPBP LINE
LPBP V/V

CRH LINE

HRH LINE
--THRO / BLANK FLANGE

-- S.H & MS LINE

June
27, 2015
--UN TREATED PIPE

-- R.H & HRH


-- LPBP

LPBP V/V

TO CONDENSER

-- PERMANENT PIPING

-- CRH & HPBP


--TARGET PLATE

-- TEMPORARY PIPING

PMI

SUGGESTED
STAGE-2
FLANGES
COVERS
A,B,"D&"E
BLOWING
S.H,
MS
JUMPER
STEAM
DESH
MS
STOP
INBLOWING
CRH
LINE
VALVES
LINE
CONN.
IN
IS
ISTO
TO
NOT
BE
CRH
TO IS
-- OPEN
PRESSURE
LINE,JUMPER
ARE
BLANKED,
IS AFTER
FROM
CONNECTING
C IS50KscTO
CARRIED
BE
TO
OPEN
BE
ERECTED
CONDITION
TAKEN
OUT
USING
EOTVs
EOTVS
Revision
00
47
-- CLOSE
25
ESV
OPENED
Ksc
& CRH LINE
INSTALLED
FOR STAGE-1

STAGE-IIB

EOTV

MS STOP V/V

R
H
O

R
H
I

H
D
R

D
E
S
H

S
H
I
H

BACK TO
INDEX

A
C
D

ESV

S
H
O
H

M
S
L

H
D
R

THRO / BLANK
FLANGE

C
R
H

HOTVs

N
R ESV
V

EOTV

HPBP SPOOL
PIECE 450

HPBP LINE
LPBP V/V

CRH LINE

HRH LINE
--THRO / BLANK FLANGE

-- S.H & MS LINE


-- CRH & HPBP

--TARGET PLATE

June
27, 2015
--UN TREATED PIPE

-- R.H & HRH


-- LPBP

-- TEMPORARY PIPING

LPBP V/V

TO CONDENSER

-- PERMANENT PIPING

-- OPEN
PMI Revision
-- CLOSE

FLANGES
STEAM
STAGE-2B
BLOWING
A,"D&"E
COVERS
ISIS
S.H,
TO
ARE
BE
MS
DESH
EOTVs
IN
ARE
CRH
INLINE
CLOSED
NOT
TO
BLANKED,
CARRIED
LINE,H.P
BYPASS
OUT
B&C
USING
LINE&
ARE
MSCRH
CONDITION
BE
ERECTED
00
48
OPENED
STOP
LINE
VALVES

STAGE-IIIA

EOTV

MS STOP V/V

R
H
O

R
H
I

H
D
R

S
H
I
H

D
E
S
H

BACK TO
INDEX

A
C
D

ESV

S
H
O
H

M
S
L

H
D
R

THRO / BLANK
FLANGE

C
R
H

HOTVs

N
R ESV
V

EOTV

HPBP SPOOL
PIECE 450

HPBP LINE
LPBP V/V

CRH LINE

HRH LINE
--THRO / BLANK FLANGE

-- TEMPORARY PIPING

-- S.H & MS LINE

-- PERMANENT PIPING

-- CRH & HPBP


--TARGET PLATE

June
27, 2015
--UN TREATED PIPE

-- R.H & HRH


-- LPBP

PMI

LPBP V/V

TO CONDENSER

SUGGESTED
MS
FLANGES
STEAM
STAGE-3A
DESH
STOP
INBLOWING
CRH
VALVES
A,B&"E
COVERS
BLOWING
LINEARE
ISCAN
S.H,
TOARE
BE
MS
BE
-- OPEN
IN00
BLANKED,
CARRIED
LINE,JUMPER
ERECTED
PRESSURE
OPEN CONDITION
OUT
C&D
IS CONNG.
50
USING
KscTO
ARE
EOTVs
ESV
25Ksc
Revision
49
-- CLOSE
OPENED
&CRH
LINE,CRHLINE,R.H,HRH

STAGE-IIIB

EOTV

MS STOP V/V

R
H
O

R
H
I

H
D
R

D
E
S
H

S
H
I
H

BACK TO
INDEX

A
C
D

ESV

S
H
O
H

M
S
L

H
D
R

D
C
R
H

THRO / BLANK
FLANGE

N
R ESV
V

HOTVs

EOTV

HPBP SPOOL
PIECE 450

HPBP LINE
LPBP V/V

CRH LINE

HRH LINE

--THRO / BLANK FLANGE

-- TEMPORARY PIPING

-- S.H & MS LINE

-- PERMANENT PIPING

-- CRH & HPBP


--TARGET PLATE

June
27, 2015
--UN TREATED PIPE

-- R.H & HRH


-- LPBP

PMI

TO CONDENSER
LPBP V/V

DESH
INBLOWING
CRH
LINEIN
BE
STAGE-3B
FLANGES
A,B&"D
COVERS
S.H,
MS
STEAM
MS STOP
VALVES
ISCAN
TOARE
-- OPEN
ERECTED
LINE,JUMPER
BLANKED,
C,"E
CONNG.ESV
ARE
&
CARRIED
OPEN
CONDITION
OUT
USING
EOTVS
Revision
00
50
-- CLOSE
CRH,CRH
OPENED LINE,R.H,HRH,LPBP

BACK TO
INDEX

STAGE-IV A
FROM CROSS
AROUND PIPES

NEAR DEAERATOR

FROM IP / LP CROSS
AROUND TO DEAERATOR

FROM CRH

CRH-1

CRH-3

FROM IP / LP CROSS
AROUND PIPE
CRH-4

CRH-2

FROM APRDS
HEADER

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BACK TO
INDEX

STAGE-IV B
FROM CROSS
AROUND PIPES

NEAR DEAERATOR

FROM IP / LP CROSS
AROUND TO DEAERATOR

FROM CRH

CRH-1

CRH-3

FROM IP / LP CROSS
AROUND PIPE
CRH-2

FROM APRDS
HEADER

June 27, 2015

CRH-4

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COMMISSIONING
OF FANS
AIRPREHEATERS

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COMMSSIONING OF LUB OIL


SYSTEM

HYDROTEST OF LUB OIL LINES.


HYDROTEST OF COOLERS.
ACID CLEANING OF LUB OIL LINES.
TRIAL RUN LUB OIL MOTORS.
OIL FILLING
LUB OIL FLUSHING.
CONNECTION OF LUB OIL LINES.

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ACID CLEANING.
1.DM WATER FLUSHING FOR 10min.
2.SOAKING WITH 5%HCL SOLUTION AND INHIBITOR
0.2% RHODINE 213 SPL.SOAKING TIME-4 HRS.
3.DRAINIG OF ACID SOLUTION AND FLUSHING WITH
DM WATER FOR 10MIN.
4.SOAKING WITH SODIUM NITITRITE(2%) AND LIQUOR
AMMONIA 5% FOR 30MIN.
5. FLUSHING WITH DM WATER FOR 10MIN.
6.CLEANING OF ALL PIPES BY BLOWING WITH
COMPRESSED AIR FOR DRYING PURPOSE.
7. FILLING OF OIL PIPELINE AND ENSURING UNIFORM
COATING OF OIL FILM OVER ENTIRE INNER
PERIPHERY.
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LUB OIL FLUSHING .


LUB OIL FLUSHING WITH BYPASSING BRGS
AND SERVOMOTOR.
LUB OIL FLUSHING WITH BRGS. AND
SERVOMOTOR IN CIRCUIT.
COOLING WATER GOING TO LUB OIL COOLERS
FLUSHING.
RELIEF VALVE PRESSURE ADJUSTMENT.

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MOTOR NO LOAD TRIAL


FOR FD/PA FANS.

CHECK FOR THE CABLING OF MOTOR.


CHECK FOR PROPER EARTHING OF MOTOR.
CHECK FOR ROTOR FREENESS.
CHECK FOR CONTROL ROOM INDICATIONS OF
BRG TEMP AND VIBRATIONS.
CHECK FOR THE LOCATION OF EPB.
ENSURE GREASING OF MOTOR BRGS.

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COMMISSIONING OF
FD/PAFANS

CHECK FOR THE FREENESS OF FAN ROTOR.


CHECK FOR THE INDICATION OF RTD AND
VIBRATION PICKUPS.
CHECK THE OPERATION BLADE PITCH IN
CONTROL ROOM AS WELL AS IN LOCAL.
CHECK FOR THE OPERATION OF DISCHARGE
DAMPER/GATE.

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COMMISSIONING OF
FD/PA FANS

CHECK WHETHER ALL PROTECTIONS AND


PERMISSIVES ARE IN SERVICE.
CHECK FOR THE CLEANLINESS OF
DISCHARGE DUCT AND ALL OTHER
INTERCONNECTION OF DUCTS.
CHECK FOR THE CLEANLINESS OF SUCTION
CHAMBER.
CHECK FOR BLADE CLEARANCES FROM THE
FAN CASING.
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COMMISSIONING OF
FD/PA FANS

CHECK FOR THE AVAILABLITY OF COOLING


WATER.
CHECK WHETHER LUB OIL COOLERS ARE
CHARGED FROM WATER SIDE.
TAKE THE TRIAL RUN OF FAN AFTER GETTING
CLEARANCES FROM VERIOUR CONCERNED
DEPARTMENTS.
BRG TEMP,VIBRATION READINGS TO BE
RECORDED ON HOURLY BASIS.
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MOTOR NO LOAD TRIAL


FOR ID FANS.

CHECK FOR THE CABLING OF MOTOR.


CHECK FOR PROPER EARTHING OF MOTOR.
CHECK FOR ROTOR FREENESS.
CHECK FOR CONTROL ROOM INDICATIONS OF
BRG TEMP AND VIBRATIONS.
CHECK FOR THE LOCATION OF EPB.

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MOTOR NO LOAD TRIAL


FOR ID FANS.

CHECK FOR THE AVAILABILITY OF MOTOR


COOLING WATER.
CHECK FOR OIL LEVEL IN BRGS.
CHECK FOR THE HEALTYNESS OF COOLING
WATER FLOW SWITCH.
ENSURE THE FLUSHING COOLING WATER
LINES TO MOTOR.

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COMMISSIONING OF ID FANS
CHECK FOR THE FREENESS OF FAN ROTOR.
CHECK FOR THE INDICATION OF RTD AND
VIBRATION PICKUPS.
CHECK THE OPERATION OF IGV IN CONTROL
ROOM AS WELL AS IN LOCAL.
CHECK FOR THE OPERATION OF DISCHARGE
GATE/INLET AND OUTLET GATES.

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COMMISSIONING OF ID FANS
CHECK WHETHER ALL PROTECTIONS AND
PERMISSIVES ARE IN SERVICE.
CHECK FOR THE CLEANLINESS OF
DISCHARGE DUCT AND ALL OTHER
INTERCONNECTION OF DUCTS.
CHECK FOR THE CLEANLINESS OF SUCTION
CHAMBER.
CHECK FOR BLADE CLEARANCES FROM THE
FAN CASING.
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COMMISSIONING OF ID FANS
ENSURE THE FLUSHING OF JACKET COOLING
WATER DONE BEFORE.
ENSURE LUB OIL LINE VALVES GOING TO
INDIVIDUAL BRGS ARE IN OPEN CONDITION.
FAN TO BE STARTED AND TRIAL RUN TO BE
TAKEN FOR 8HRS.

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PRECOMMISSIOING CHECKS
OF
AIR
PREHEATERS
CHECK FOR
RADIAL
CLEARANCE OF RADIAL

SEALS AS PER DESIGN.


CHECK FOR AXIAL CLEARANCE OF AXIAL
SEALS AS PER DESIGN.
CHECK FOR PROPER CLEARANCE OF
CIRCUMFERENTIAL SEALS.
CHEACK FOR THE CLEANLINESS OF AIR
PREHEATER BASKETS.

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PRECOMMISSIOING CHECKS
OF
AIR PREHEATERS

ENSURE THE CLEANING OF PROTECTIVE


COATING OF AIRPREHEATER.
CHECK FOR TRAVEL PATH OF AIRPREHEATER
SOOTBLOWING.
ENSURE THAT NO LOOSE PARTS ARE HANGING.
BEFORE STARTING AIRPREHEATER ALL MANUAL
DOORS ARE PROPERLY TIGHTENED.

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COMMISSIOING OF AIR
PREHEATERS

ENSURE THE COMPLETION OF MOTOR NO


LOAD TRIAL RUN FOR 8HRS.
ENSURE THE COMPLETION OF LUB OIL
FLUSHING OF SUPPORT/GUIDE BRGS.
FLUSH THE COOLING WATER LINES.
CHECK FOR THE CLEANLINESS OF AIR
RECEIVER TANK.
FLUSH THE SERVICE AIR LINES GOING TO AIR
RECEIVER TANK.
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COMMISSIOING OF AIR
PREHEATERS

FLUSH THE OIL CARRYOVER PROBE COOLING


LINES.
FLUSH AIRPREHEATER WATER WASH LINES.
ENSURE THE CLEANLINESS OF WATER WASH
LINE NOZZLES.
ENSURE THAT FIRE FIGHTING LINES ARE
CONNECTED AS PER DRAWING.

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COMMISSIOING OF AIR
PREHEATERS

ENSURE FLUSHING OF FIRE WATER LINES.


ENSURE THE CLEANLINESS OF FIRE FIGHTING
NOZZLES.
CHECK FOR THE PROPER PLACING FIRE
SENSING PROBES.
FLUSH AIR LINE COMING FROM AIR RECEIVER
TANK.

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COMMISSIOING OF AIR
PREHEATERS

CHECK FOR HEALTHINESS OF SUPPORT


BRG/GUIDE BRG RTDS.
ROTATE FREELY WITH HAND AND OBSERVE
ANY ABNORMAL SOUND.
START AIR PREHEATER WITH AIRMOTOR AND
ROTATE IT FOR SOMETIME.
START MAIN DRIVE OF AIRPREHEATER.

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COMMISSIOING OF AIR
PREHEATERS

CHECK THE AIRPREHEATER MAIN DRIVE TO


AIRMOTOR CHANGEOVER INTERLOCK
HEALTINESS.
CHECK FOR VIBRATIONS OF MAIN DRIVE.
CHECK FOR THE HEALTHYNESS OF AIRMOTOR
PRESSURE SWITCHES.

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READINESS FOR FIRST BOILER LIGHT UP

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SAFETY VALVE FLOATING OF MAIN BOILER


OBJECTIVE:
To test the safety valves by actually floating and ensure that
safety valves lift at recommended values.
Location

Make

Drum
SH Outlet SV
ERV

No.

BHEL

2
4

207.0, 209.0 211.1,


211.1 213.2 213.2

BHEL

2
5

188.5, 188.5 185.5,


185.5, 186.6 186.6,
186.6

BHEL

52.4, 52.4, 54.0, 54.0

BHEL

4
4

49.4, 49.4, 50.9, 50.9


48.4, 48.4, 48.9, 48.9

Safety
Valves
RH

June 27, 2015

Inlet
Outlet

Set Pr. Kg/cm2 g

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SAFETY VALVE FLOATING OF MAIN BOILER


Test all the safety valves one by one by actually raising the pressure of
the boiler to set values of the valves and also to set the blowdown of
the valve within 3% - 5% of the set value.
Safety valve with higher set pressure will be floated first followed by
other valves in descending order of set valves. If set pressures are same
for few valves, then any valve can be taken for floating.
When the pressure reaches around 180-190 KSC, the safety
valves is warmed up by manual popping and for this, the popping
arrangement provided is made use off through rope. Once or
twice the manual popping done to clear the safety valves path and
also
warm
Juneto27,
2015up the valve. PMI Revision 00

79

THANK YOU

June 27, 2015

PMI Revision 00

80

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