Boiler Commissioning
Boiler Commissioning
COMMISSIONING
June 27, 2015
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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.
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INTRODUCTION TO COMMISSIONING
Organization
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INTRODUCTION TO COMMISSIONING
Documentation
1. Papers of principle Prepared jointly by
Erection and corporate O.S.
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INTRODUCTION TO COMMISSIONING
Documentation
2. Testing & commissioning Schedule
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INTRODUCTION TO COMMISSIONING
Documentation
3. Standard checklist
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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
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--------------------------------------------------------------------------------------------------------------------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
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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
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CHEMICALS REQUIREMENT
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Acid cleaning
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STEAM BLOWING
OF
BOILER AND
ASSOCIATED STEAM LINE
INCLUDING
AUXILIARY STEAM LINES
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STEAM BLOWING
BACK TO
INDEX
OBJECTIVE:
TECHNIQUE:
PROCEDURE:
SEVEN STAGES AS
44
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
-- 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
--TARGET PLATE
June
27, 2015
--UN TREATED PIPE
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
June
27, 2015
--UN TREATED PIPE
LPBP V/V
TO CONDENSER
-- PERMANENT PIPING
-- 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
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00
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-- 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
--TARGET PLATE
June
27, 2015
--UN TREATED PIPE
-- TEMPORARY PIPING
LPBP V/V
TO CONDENSER
-- PERMANENT PIPING
-- OPEN
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-- 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
-- PERMANENT PIPING
June
27, 2015
--UN TREATED PIPE
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
-- TEMPORARY PIPING
-- PERMANENT PIPING
June
27, 2015
--UN TREATED PIPE
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
TDBFP-A
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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
CRH-4
TDBFP-A
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COMMISSIONING
OF FANS
AIRPREHEATERS
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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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COMMISSIONING OF
FD/PAFANS
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COMMISSIONING OF
FD/PA FANS
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COMMISSIONING OF
FD/PA FANS
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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
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PRECOMMISSIOING CHECKS
OF
AIR PREHEATERS
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COMMISSIOING OF AIR
PREHEATERS
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COMMISSIOING OF AIR
PREHEATERS
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COMMISSIOING OF AIR
PREHEATERS
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COMMISSIOING OF AIR
PREHEATERS
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COMMISSIOING OF AIR
PREHEATERS
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Make
Drum
SH Outlet SV
ERV
No.
BHEL
2
4
BHEL
2
5
BHEL
BHEL
4
4
Safety
Valves
RH
Inlet
Outlet
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THANK YOU
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