Boiler Commissioning Procedure

PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure PT.PLN(PERSERRO)

Owner’s

0702-00-M-01-HL-002

DWG No.

PT REKADAYA

PT.PLN(PERSERRO)

ELEKTRIKA

JAVA MANAJEMEN KONSTRUKSI

CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY DETAIL SiChuan Electric Power Commissioning &

PLTU 1 Jatim-Pacitan (2×315MW)

Test Institute

Project

Approval

Check

Review

Design

Date

Scale

DESIGN STAGE

Procedure of Air Preheater System N/A

DWG No.

SCCTI-TS-GL-CS-012-2009A

REV

A

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure

Procedure of Air Preheater System

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Table of Contents 1. PURPOSE ..............................................................................................................................................................3 2. SCOPE ...................................................................................................................................................................3 3. PREPARATION BASIS.........................................................................................................................................3 4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .................................................................................3 5. TOOLS AND INSTRUMENT FOR COMMISSIONING.....................................................................................4 6. PREREQUISITE FOR COMMISSIONING .........................................................................................................4 7. MEASURES FOR COMMISSIONING ORGANIZATION .................................................................................6 8. COMMISSIONING PROCEDURE ......................................................................................................................7 9. SAFETY MEASURES ........................................................................................................................................14

9.1 Safety Rules for Commissioning.......................................................................................... 14 9.2 Personal Risk and Preventative Measures............................................................................ 14 9.3 Equipment Risk and Preventative Measures ........................................................................ 14 10. APPENDIX ........................................................................................................................................................14

Appendix 1 Commissioning Condition Checklist...................................................................... 15 Appendix 2 Parameter Record for Trial Run of APH and Its System........................................ 17 Appendix 3

Commissioning Record Format of Dampers of APH System ....................... 19


1.


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Purpose

1.1

Provide a guideline and set specifications for the commissioning work of system and equipment so as to guarantee that the system and equipment will be able to put into operation normally and safely.

1.2

To check electric and I&C protection, interlock and signal devices and confirm their proper operation.

1.3

To check equipment running, verify system performance, and detect and remove any potential defects.

2.

Scope This procedure is applicable to sub-system commissioning of air preheater(APH) system. The commissioning starts from dynamic taking over and acceptance after completion of individual commissioning of APH, including the items of damper baffle confirmation, test of interlock protection, system in service and dynamic adjustment.

3.

Preparation Basis

3.1

Boiler equipment operation manual and flue-gas and air system chart.

3.2

Operation and Maintenance Manual of Air Preheater

3.3

Installation Manual of Air Preheater

3.4

Local control cabinet manual and design drawings of APH.

3.5

Purchased equipment manual and design drawings of APH.

4.

Brief Description of System and Equipment

4.1

There are two sets of APHs both for operation. Vertical model is used; the structure is Tri-sectional regenerative and the flue gas flows downwards.

4.2

Seal of APH The radial, axial and circumferential seal system is used in APH and the double seal structure of radial to axial and radial to bypass which has a short perimeter and proper effect. It is also equipped with seal clearance automatic tracing control device which has an automatic thermal compensation with reliable electronic sensing element. The double seal system can make each fan shape plate, at least there are two plate of radial and axial seal device to coordinating at any time when the rotor rotates to form two courses of seal which makes the pressure differential at the seal place reduce to half and the air leaking is directly dropped to about 30 ％.

4.3

Wash device and fire alarming system of APH The fixed flushing pipelines are provided on hot end and cold end of the flue gas side of each APH respectively. The flushing pipeline is installed at the startup side near the flue gas side as per the rotation direction of the rotor to facilitate the flushing water to be drained from the ash hopper at the flue gas side. The flushing media is constant temperature industrial water P＝ 0.59MPa. If water with temperature of 60～70℃ is used, the washing effect can be much better. The flushing pipeline is also used for fire fighting.



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The fire alarm system is a horizontal shifting and infrared ray monitored installed in the air side of the lower part of APH and has a good monitoring effect. 4.4

Soot blower of APH An expansion soot blower with forward intermission and backward direct-acting is installed in cold end of the flue gas side of each APH. The steam source for soot blower comes from the header of platen superheaters and auxiliary steam.

4.5

Technical Parameters of APH Model: 29VNT1920

Main motor

Auxiliary motor

Model:

Y160L-6B5

Y160L-6B5

Power

11KW

11KW

Voltage

380V

380V

Current

24.6A

24.6A

Motor rotation speed

970rpm

970rpm

Insulation class

B

B

Air preheater rotation speed

1.14rpm

0.507rpm

Manufacturer

Dongfang Boiler Group Co,. Ltd.

5.

Tools and Instrument for Commissioning

5.1

Walkie talkie

5.2

Digital multimeter

6.

Prerequisite for Commissioning Before formally beginning system commissioning, commissioning persons should conduct comprehensive checks on conditions that should be available for commissioning of this system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and make well the records.

6.1

Environmental Conditions The ground within the system shall be level, the road free, covers for the trench complete and the environment is clean without sundries. The platforms, ladders, railings and guard sheets within the range of the system shall be complete and the scaffoldings have been removed completely.

6.1.1

There shall be enough permanent illumination and temporary illumination shall be provided, if necessary.

6.1.2

There is reliable communication equipment at the site.

6.1.3

There are enough fire fighting apparatuses available at the site.

6.2

Conditions that must be available for machinery provisions

6.2.1

The installation of insulations for equipments, pipelines and auxiliary system of APH is completed.



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6.2.2

Single trial run of APH is qualified.

6.2.3

The installation and commissioning of the thin oil station is completed.

6.2.4

The oil level in redactor is normal and operation of the pump of the redactor is normal.

6.2.5

The installation and commissioning of the industrial cooling water system is completed.

6.2.6

The sundries inside the APH and its system are cleaned completely.

6.2.7

The installation and commissioning of alkali flushing system of APH is completed.

6.2.8

The name plates for equipments and valves are already tagged and matched to the system.

6.2.9

Doors of all manholes in the system are closed.

6.3

Conditions that must be available for electrical and I&C

6.3.1

The measurement points and measurement elements inside the fuel oil system have been successfully installed and commissioned after the calibration is satisfactory and ready for operation.

6.3.2

The commissioning of thin oil station is completed and a proper operation is confirmed, the parameter is normal and CRT status indication is correct.

6.3.3

Commissioning of clearance adjustment device of APH is completed.

6.3.4

Commissioning of fire alarming device of APH is completed

6.3.5

The commissioning of single valve is completed, the open and close action is normal, the local position and CRT status indication of limit switch is correct.

6.3.6

Test of interlock protection alarm of APH is completed.

6.3.7

Electrical test of motors is qualified, idle run for 2h and operation is proper and rotating direction is correct.

6.4

Other preconditions required to be available

6.4.1

The parties of Dongfang Electric, Owner, production and commissioning had been organized to conduct the large joint inspection, the problem, if found any, was rectified.

6.4.2

The preparation for production trial run has been completed and enough numbers of operators have been deployed and trained and passed the examination. The operation regulations and system chart have been approved, operation tools are available and the operation log is ready.

6.4.3

Prepare maintenance tools and materials necessary for commissioning;

6.4.4

The commanding organization of the trial run is established and work division is clear. The materials, tools, instruments, meters and record formats to be used in commissioning are ready and complete.

6.4.5

The commissioning personnel concerning I&C, electrical and mechanical of the installation contractor are available at site.

6.4.6

The clarification of measures is completed.


7.


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Measures for Commissioning Organization This procedure shall be executed under the organization of commissioning contractor. The construction contractors shall cooperate closely with each other according to their respective work responsibilities so as to guarantee safe and effective implementation of commissioning. The division of works is as follows:

7.1

Responsibilities of Commissioning Contractor ◆ Preparation and revision of commissioning procedures; ◆ Preparation of commissioning plan; ◆ Preparation of instruments and equipment required for commissioning； ◆ Hold technical disclosure meeting for commissioning; ◆ Organize the commissioning work to be carried out by various parties; ◆ Give instructions to operators in the operation; ◆ Prepare commissioning report.

7.2

Responsibilities of Installation Contractor ◆

Be responsible for individual commissioning of equipment and provide relevant record and certificate of commissioning;

◆ Be responsible for inspection, maintenance and defect elimination of equipment under commissioning； ◆ Prepare maintenance tools and materials necessary for commissioning； ◆ Assist the commissioning contractor in the commissioning of subsystems； ◆ Be responsible for temporary coordination of local I&C components and connection terminals. 7.3

Responsibilities of Equipment Manufacturers ◆ Representative of manufacturer, if present on the site offering service, shall provide technical assistance during equipment commissioning.

7.4

Responsibilities of Plant Operator ◆ Prepare tools to be involved in operation; ◆ Prepare operation log and forms; ◆ Operate the system and equipment according to the operating procedures and the instructions of the commissioning personnel; ◆ Be responsible for patrol inspection, check, and normal maintenance of system and equipment; ◆ Be responsible for dealing with the accidents occurred in commissioning。

7.5

Responsibilities of Dongfang Electric ◆ Be responsible for supervision and control over commissioning work;



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◆ Coordinate with commissioning contractor, the Owner, and other contractors in the commissioning. ◆ Participate in and witness the commissioning work; ◆ Organize analysis and settlement of major technical issues in commissioning。 7.6

Responsibilities of Owner ◆ Supervise the execution of commissioning procedures; ◆ Witness the commissioning work; ◆ Accept the results of commissioning。

8.

Commissioning Procedure

8.1

Check and accept flue gas and air baffle and record the following data: Check for correctness of KKS code, designation, local position indication, remote operating direction, feedback, time used in open and close of damper, signature of person concerned. Refer to Appendix 2.

8.2

Interlock Protection and Alarms Check (Note: the result of logic discussion will prevail for the test items of the interlock protection).

8.2.1

Place the power supply to the test position and check the following items:

8.2.2 No.

(1)

APH is started up by a computer and the feedback is correct.

(2)

APH is shut down by a computer and the feedback is correct.

(3)

The work of emergency button is reliable.

Check for alarm signal of APH A (B) Test item

Check of alarm signal of APH A

(1) Alarm from fire detector of APH A (2) Rotor rotating of APH A stop (3) Alarm of guidance bearing temperature≥70℃of APH A (4) Alarm of thrust bearing temperature≥70℃of APH A (5) Alarm of guidance bearing oil station failure of APH A (6) Alarm of thrust bearing oil station failure of APH A Check of alarm signal of APH B (1)

Alarm from fire detector of APH B

(2)

Rotor rotating of APH A stop

(3)

Alarm of guidance bearing temperature≥70℃of APH B

(4)

Alarm of thrust bearing temperature≥70℃of APH B

Fixed value

Results

Remark s



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(5)

Alarm of guidance bearing oil station failure of APH B

(6)

Alarm of thrust bearing oil station failure of APH B

8.2.3 No.

Check for permissive conditions for APH A (B) Startup Test item

Fixed value

Results

Remarks

Fixed value

Results

Remarks

Check of permissive conditions of APH A startup (1)

No APH integrated troubles in APH A

(2)

Auxiliary motor of APH A has been shut down

(3)

Power supply for main motor of APH A not broken

(4)

Main motor of APH A on remote control state

(5)

Main motor of APH A shutdown

(6)

Oil station of guidance bearing of APH A ready

(7)

Oil station of thrust bearing of APH A ready

(8)

Reductor oil pump of APH A shutdown

Check of permissive conditions of APHB startup (1)

No APH integrated troubles in APH B

(2)

Auxiliary motor of APH B has been shut down

(3)

Power supply for main motor of APH B not broken

(4)

Main motor of APH B on remote control state

(5)

Main motor of APH B shutdown

(6)

Oil station of guidance bearing of APH B ready

(7)

Oil station of thrust bearing of APH B ready

(8)

Reductor oil pump of APH B shutdown

8.2.4 No.

Permissive conditions for APH shutdown Test item

Permissive conditions for APH A shutdown (1)

Inlet flue gas temperature of APH A <205℃

(2)

Both ID fan A and FD fan A shutdown

Permissive conditions for APH B shutdown (1)

Inlet flue gas temperature of APH B <205℃

(2)

Both ID fan B and FD fan B shutdown

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure 8.2.5 No.


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Termination conditions for interlock protection of APH Test item

Fixed value

Termination conditions for interlock protection of APH A

(1) emergency button in motion (2) Reductor oil pump of APH A tripped Termination conditions for interlock protection of APH B

(1) emergency button in motion (2) Reductor oil pump of APH B tripped

8.2.6

Startup condition for interlock of main and auxiliary motors of APH

Results

Remarks


No.


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Test item

Fixed value

Results

Remarks

Startup conditions for main and auxiliary motors interlock of APH A (1)

Under the standby in service conditions, the auxiliary motor of APH A failed or shutdown and the corresponding main motor is started up by interlock.

(2)

Under the standby in service conditions, the auxiliary motor of APH A failed or shutdown and the corresponding auxiliary motor is started up by interlock.

Startup conditions for main and auxiliary motors interlock of APH B (1)

Under the standby in service conditions, the auxiliary motor of APH B failed or shutdown and the corresponding main motor is started up by interlock.

(2)

Under the standby in service conditions, the auxiliary motor of APH B failed or shutdown and the corresponding auxiliary motor is started up by interlock.

8.2.7

Interlock test of outlet primary and secondary dampers and inlet flue gas baffle of APH

No.

Test item

(1)

Main motor or auxiliary motor of this side APH is in operation and the outlet primary and secondary dampers and inlet flue gas baffle are opened by interlock

(2)

At the request of FSSS natural draft, delaying for 15s, the outlet secondary damper and inlet flue gas baffle are opened by interlock

(3)

Main motor or auxiliary motor of this side APH is out off operation and there is no request of natural draft from FSSS, the outlet primary and secondary dampers and inlet flue gas baffle are closed by interlock

8.2.8 No.

Fixed value

Results

Remarks

Interlock Protection Test of APH Oil Station(B is same as A) Test item

Oil station interlock protection of APH A (1)

Standby pump is started up by interlock when oil pressure is low (0.12MPa)

(2)

Oil pump failure, standby pump is started by interlock and failure alarms

(3)

Standby pump is shut down when oil pressure high (0.3MPa)

Fixed value

Results

Remarks



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(4)

Alarming and automatically starting up the pump when the guidance bearing temperature is high(>55℃)

(5)

DCS alarms when guidance bearing temperature is HH (>70℃)

(6)

Pump automatically shutting down when guidance bearing temperature is low (<45℃)

(7)

Standby pump automatically starting up when the support bearing temperature is high (>55℃)

(8)

DCS alarms when support bearing temperature is HH (>70℃)

(9)

Pump automatically shutting down when support bearing temperature is low (<45℃)

Oil station interlock protection of APH B (1)

Standby pump is started up by interlock when oil pressure is low (0.12MPa)

(2)

Oil pump failure, standby pump is started by interlock and failure alarms

(3)

Standby pump is shut down when oil pressure high (0.3MPa)

(4)

Alarming and automatically starting up the pump when the guidance bearing temperature is high(>55℃)

(5)

DCS alarms when guidance bearing temperature is HH (>70℃)

(6)

Pump automatically shutting down when guidance bearing temperature is low (<45℃)

(7)

Standby pump automatically starting up when the support bearing temperature is high (>55℃)

(8)

DCS alarms when support bearing temperature is HH (>70℃)

(9)

Pump automatically shutting down when support bearing temperature is low (<45℃)

8.2.8

Startup Sequence of APH A Sub-group (B is same as A)

No.

Test item

Startup sequence of APH A (1)

First step: startup oil station of APH

(2)

Second step: startup main or auxiliary motor of APH

(3)

Third step: open secondary air outlet damper of APH

(4)

Fourth step: open flue gas inlet baffle of APH

Fixed value

Results

Remarks



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Startup sequence of APH B (1)

First step: startup oil station of APH

(2)

Second step: startup main or auxiliary motor of APH

(3)

Third step: open secondary air outlet damper of APH

(4)

Fourth step: open flue gas inlet baffle of APH

8.2.9

Shutdown Sequence of APH A Sub-group

No.

(B is same as A)

Test item

Fixed value

Results

Remarks

Shutdown sequence of APH A (1)

First step: close flue gas inlet baffle of APH A

(2)

Second step: close primary and secondary air outlet dampers

(3)

Third step: shutdown main or auxiliary motor of APH A

Shutdown sequence of APH B (1)

First step: close flue gas inlet baffle of APH A

(2)

Second step: close primary and secondary air outlet dampers

(3)

Third step: shutdown main or auxiliary motor of APH A

8.3

APH and its system operation

8.3.1

Prior to trial operation, check that the following conditions are met: (1)

Both soot blower and flushing pipeline are ready for use immediately.

(2)

The preparation of production is ready, complete operators who have been trained and qualified for the post are deployed

(3)

The communication system is reliable and the contact is free.

(4)

The covers for trench in MPH are complete, staircase, footpath and safety guards are proper and all sundries are cleaned completely.

(5)

The industrial lighting for equipments and emergency lighting are good and proper and adequate lighting shall be ensured.

(6)

The commissioning for common systems like closed water instrument air and service air system is completed and can be put into normal operation.

(7)

I&C DCS system has the conditions to start and shut down equipment on CRT.

(8)

The sundries inside APH and at the trial run site have been cleaned completely.

(9)

Confirm that the installation of APHs and their systems are completed and the system is complete.


8.3.2

8.3.3

8.3.4


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(10

The manhole doors and maintenance hole of APHs have been sealed properly.

(11)

The installation lubrication system of guidance and thrust bearing of APHs has been completed and has charged with oil of stipulated quality and up to normal oil level. The trial run of the oil pump is qualified and the normal oil circulation and cooling water circulation has been established.

(12)

The oil level in redactor is normal.

(13)

The hydro test for oil cooler in oil station system of APHs is qualified and the system has the conditions for putting into service.

(14)

The drive test for interlock protection concerning the oil station of APHs is qualified.

(15)

Adjustment of protection and alarm setting has been completed.

(16)

Electrical test and interlock test have been completed.

(17)

The single trial run of APHs and their motors has been completed.

(18)

Manual rotating PH and its rotor has been normal and the cold commissioning of air leakage control device has been completed.

(19)

The check and drive of related flue gas baffle has been completed and normal in service.

(20)

Reliable operation and power supply is available.

(21)

Connection of motor is proper and insulation shall be qualified.

(22)

The installation calibration of I&C and electrical instrument related to trial run have been completed and can be put into service.

(23)

The installation and commissioning of fire alarming device and shutdown alarm device of APH have been completed and the devices are normal in service.

Startup preparation for APHs and their system (1)

Put the instrument air compressors and cooling water system into service.

(2)

Turn on power supply of APHs and air source and power for air motor.

(3)

The oil level and temperature of APH guidance and thrust bearings are normal.

(4)

Oil level in the redactor is normal.

(5)

Confirm that the APH startup permissive conditions on DCS are met.

Startup of APH (1)

Start up the motor of APH and shutdown the same when the current drops back. Check APH for correct rotating direction and whether there is abnormal condition.

(2)

If there is no abnormal condition, restart the motor of APH.

(3)

Trial run the APHs and their system for 8h and monitor the operation parameters which shall be in a normal range during the trial run.

System operation in the stage of complete set operation (1)

The complete operation is divided into stages of non-load, with load, full load and 30d reliable operation to test the reliability of operation of the system under various work



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conditions. (2)

During the process of putting APH and the system into operation and especially when dynamic adjustment of the system is being carried out, the monitor to all equipments in the system shall be enhanced. Timely adjustment shall be done when there is deviation from normal operation to ensure that the system is in the best operation state. The parameters of temperature of all bearings, motor current, outlet and inlet air pressure, air temperature and flue gas temperature under different load condition shall be recorded completely.

9.

Safety Measures

9.1

Safety Rules for Commissioning

9.1.1

The parties participating in the commissioning will be ware of and observe relevant safety regulations on the site, wear proper clothes and personal safety protection articles.

9.1.2

In case of any accident that damages the equipment or hurts person happened or possibly happen during commissioning, suspend commissioning immediately and put the equipment to the lowest energy state. Then investigate the cause and take corrective measures.

9.1.3

The parties participating in the commissioning shall obey the command of commissioning personnel. In case there is an emergency endangering personal or equipment safety, any person has the right to stop the operating equipment immediately and report to the control room.

9.2

Personal Risk and Preventative Measures

9.2.1

Injuries might be caused by rotating equipment during commissioning or test. Therefore, special care must be taken during work and do not touch the rotating components with tools or your hand。

9.3

Equipment Risk and Preventative Measures

9.3.1

When APHs and their system are started for the first time, people in concerned companies must be at site the equipment to seriously monitor the equipment. There are reliable communication measures to contact with CCR.

9.3.2

The soot blowing of APH shall continuously put into service when the oil guns are in service at the initial stage of boiler lighting up. The discontinuous soot blowing of APH can be done when the firing is stable and the oil guns are out of service.

9.3.3

Professionals from all specialties shall be at the post during the whole process of trial run to ensure safe operation of the equipments.

9.3.4

The person works in commissioning shall give order immediately to stop the operation and break down the commissioning when the APH in operation knocks seriously the mill, the swing of motor current is too large and even exceeds the rated current and the operation parameters are over specification. The commissioning of the equipment cannot continue until the cause has been analyzed and the problems have been solved.

10.

Appendix



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Appendix 1 Commissioning Condition Checklist No. 1.

Items

Requirements

Result

Environmental Conditions

(1)

Site, road and environment

Flat, clear and clean

□Yes □No

(2)

Platform, ladder, handrail, guard plate and scaffold

Complete Removed

□Yes □No

(3)

Illuminating

Sufficient

□Yes □No

(4)

Communication equipment

Reliable

□Yes □No

(5)

Fire apparatus

Sufficient in quantity and easy for use

□Yes □No

2.

Mechanical conditions

(1)

Erection and insulation

All fulfilled

□Yes □No

(2)

Single equipment trial run

Qualified

□Yes □No

(3)

Thin oil station

Commissioning qualified

□Yes □No

(4)

Oil level in reductor

Normal

□Yes □No

(5)

Industrial cooling water system

Commissioning completed and can be put into service

□Yes □No

(6)

Sundries inside

Cleaning finished

□Yes □No

(7)

Alkali flush system

Trial run of pumps is qualified and can be put into service

□Yes □No

(8)

Equipments and valves

plates and denomination correct

□Yes □No

(9)

Doors of manholes

All closed

□Yes □No

3.

Conditions of electrical and I&C

(1)

Measurement points and instruments

Calibration qualified and indication correct

□Yes □No

(2)

Thin oil station

Operation in order status indication correct

□Yes □No

(3)

Clearance device

Commissioning fulfilled

□Yes □No

(4)

fire alarming device

Commissioning completed

□Yes □No

Single valve

Commissioning completed, motion normal and status indication correct

□Yes □No

(5)

adjustment

Verified by

Remarks


(6)

(7) 4.


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interlock protection and alarming

Test eligible

□Yes □No

Electrical test of motor

Test is qualified, idle run for 2h and operation is proper and rotating direction is correct

□Yes □No

□Yes □No

Other conditions

(1)

Inspection of system

Completed rectified

(2)

Production preparation

Operators deployed, operation tools ready and operation log ready

□Yes □No

(3)

Overhaul tools and materials

Complete

□Yes □No

(4)

Commanding organization system

Established and division clear

(5)

Commissioning materials, tools, instruments, meters and record formats

Ready and complete

□Yes □No

(6)

Maintenance personnel

Sufficient; training passed

□Yes □No

(7)

Clarification for methods

Fulfilled

□Yes □No

Commissioning Contractor: Contractor: Owner

Date: Date: Date:

and

defect

work

□Yes □No

Operation Contractor: Dongfang Electric:

Date: Date:



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Appendix 2 Parameter Record for Trial Run of APH and Its System Parameter Record Format for Trial Run of APH and Its System Sr.No.

Item

Unit

1.

Main motor current, APH A

A

2.

Auxiliary motor current, APH A

A

3.

Top-end bearing oil temperature, APH A

℃

4.

Top-end bearing metal temperature, APH A

℃

5.

Bottom-end bearing oil temperature, APH A

℃

6.

Bottom-end bearing metal temperature, APH A

℃

7.

Main motor current, APH B

A

8.

Auxiliary motor current, APH B

A

9.

Top-end bearing oil temperature, APH B

℃

10.

Top-end bearing metal temperature, APH B

℃

11.

Bottom-end bearing oil temperature, APH B

℃

12.

Bottom-end bearing metal temperature, APH B

℃

13.

Inlet flue gas pressure, APH A

KPa

14.

Outlet/inlet flue gas differential pressure, APH A

KPa

15.

Inlet flue gas temperature, APH A

℃

16.

Outlet flue gas temperature, APH A

℃

17.

Inlet primary air temperature, APH A

℃

18.

Outlet secondary air temperature, APH A

℃

19.

Inlet flue gas pressure, APH B

KPa

20.

Outlet/inlet flue gas differential pressure, APH B

KPa

21.

Inlet flue gas temperature, APH B

℃

22.

Outlet flue gas temperature, APH B

℃

23.

Inlet primary air temperature, APH B

℃

24.

Inlet secondary air temperature, APH B

℃

Data

Remarks

25.

Commissioning Contractor:

Date:

Operation Contractor:

Date:

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure Contractor: Owner


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Date: Date:

Dongfang Electric:

Date:


Appendix 3


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Commissioning Record Format of Dampers of APH System Commissioning Record Format of Dampers of APH System

KKS

Local indication correct

Name

X0HLA10AA00 2a

APH A SECONDARY DAMPER 1

AIR

OUTLET MOTOR

X0HLA10AA00 2b

APH A SECONDARY DAMPER 2

AIR

OUTLET MOTOR

X0HFE12AA00 1

PRIMARY AIR DAMPER OF APH A

X0HLA20AA00 2a

APH B SA INLET MOTOR DAMPER 1

X0HLA20AA00 2b

APH B SA INLET MOTOR DAMPER 2

X0HFE22AA00 1

PRIMARY AIR DAMPER OF APH B

X0HNA10AA0 01a

FLUE GAS INLET DAMPER 1 OF APH A

X0HNA10AA0

FLUE GAS INLET DAMPER 2

OUTLET

OUTLET

Remote operation Direction correct

Feedback correct

Time Time of opening( open)

Time of closing (close)

Date of inspection

Result

Signature

Remarks

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure 01b


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OF APH A

X0HNA20AA0 01a

FLUE GAS INLET DAMPER 1 OF APH B

X0HNA20AA0 01b

FLUE GAS INLET DAMPER 2 OF APH B


Date: Date:

Date:


Dongfang Electric:

Date:

Date:



PT.PLN(PERSERRO)

Owner’s DWG No.

PT REKADAYA ELEKTRIKA

0702-00-M-01-EB-001 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI

CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY SiChuan Electric Power Commissioning & Test Institute Approval Review Date

c Conditio n Design Scale


DETAIL DESIGN STAGE

Procedure of Coal Handling System N/A

DWG No.


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A


Procedure of Coal Handling System

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Table of Contents 1.

PURPOSE

3

2.

SCOPE

3

3.

PREPARATION BASIS

3

4.

BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT

3

5.

TOOLS, INSTRUMENT FOR COMMISSIONING

6

6.

PREREQUISITE FOR COMMISSIONING

7

7.

MEASURES FOR COMMISSIONING ORGANIZATION

7

8.

COMMISSIONING PROCEDURE

9

9.

SAFETY MEASURES

27

9.1


27

9.2


27

9.3


27

10.

APPENDIX

27

Appendix 1

Commissioning Condition Check-list

28

Appendix 2

CHP equipment operation record format

29

Appendix 3

Trial Run Record Format of CHP

30

Appendix 4

Coal Handling Baffle Commissioning Record

32

Appendix 5

Check List for Programmed Control Startup and Shutdown and Interlock

for Equipment Flow of CHP

33



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1.

Purpose

1.1


1.2

To condition electric and I&C protection, interlock and signal devices and confirm their proper operation.

1.3

To condition equipment running, verify system performance, and detect and remove any potential defects.

2.

Scope This procedure is applicable for commissioning of CHP including cold state condition and rotation, interlock protection test of the baffle and startup and shutdown of CHP.

3.

Preparation Basis

3.1

Operation manual of system equipment;

3.2

Flow chart of CHP; and

3.3

Control logic chart of CHP.

4.

Brief Description of System and Equipment The scale of power plant new project is 2×315MW and brown coal is used as fuel. The coal is transported by marine and the scope of CHP is from the coal unloading device of seagoing vessels to raw coal hopper of MPH coal bunker, including coal unloading, storage, feeding, sieve and crushing, magnetic separation, weighting and other BOPs.

4.1

Coal unloading Two sets of coal unloading facilities for seagoing vessels are provided in CHP of this project. The upper part of the facility is open arranged, 2 berths are provided, through type of coal unloading is used and the lower part of the facility is a double belt conveyor.

4.2

Coal storage One coal yard with stacker reclaimer is provided in the first phase of the system with the total storage of 22.4×104 tons, which can meet the need of two boilers run with full load for 30 days. One set of DQL1250/1250.40 stacker reclaimer is provided in the coal yard. The coal can be fed to the system by means of two emergency ground coal hoppers and C-07belt conveyor when the stacker reclaimer is failed. One set of BG-4 gravity variable coal feeder is provided for each emergency ground coal hopper.

4.3

Screen and crusher The crusher house is arranged by misalignment and there are two sets of coal screening and crushing equipments in the house. Two sets of HCSZ-1000 ring hammer crushers and SBS600 roller screens are used, one set for operation and another for standby or the two sets can operate at the same time for a short time. The comb vibration screen has a bypass system.

4.4

Belt conveyor system All the belt conveyor systems, except C-3belt conveyor which enters and leaves the coal yard, are two-ways, one for operation and another for standby. They also can provide cross



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operation and meet the need of two ways operating at the same time. Electric two-side plough tripper is used in belt layer of coal bunker room to distribute coal. 14 sets of belt conveyers are used in the system with belt width of 1200mm, speed of 3.5m/s and output of 1250t/h. 4.5

Main Equipment Specification

4.5.1

Coal unloading unit No.

Description

Model & code

Unit

Q'ty

1

ship unload unit

Q=1250t/h,

Set

2

2

sampler for coal entering the plant

BMCⅢ

Set

2

3

gas bag spray dust suppression unit for coal unloading

Operating pressure 1.0~1.2MPa Water used15m3/h

Set

1

4.5.2

Remarks

Equipments in coal yard No.

Description

Model & code

Unit

Q'ty

1

Stacker reclaimer

DQL1250/1250.40 model stacker reclaimer with 1250t/h output of stacking and 1250t/h output of reclaiming and with 40m of cantilever turn radius

Set

1

2

Head expansion unit of rubber belt machine (two positions)

JS.120/320 mode, 3.2m range, applicable belt width of B=1200mm,V=3.5m/s and with provision of local control casing and program control casing

Set

1

3

hydraulic auto tightening unit

DYL-01-6/17 model with local control casing, 5.5kW power of motor in hydraulic pump station and allowing local and remote control

Set

1

4

booster pump

Flow Q＝100m3/h；head 25m；power 15kW, 380V

Set

2

5

Submerge dredge pump

Flow Q＝15m3/h；head 25m；power 7.5kW, 380V

Set

1

6

cantilever electromagnetic separator

self provided trolley traveling mechanism with program controlled cabinet and applicable for belt width of B=1200mm

Set

1

7

Electric single-side plough tripper

DTII04F11 model, variable chute angle, applicable for belt width of B=1200mm, with single-side hopper and swing gate

Set

1

8

bulldozer

TY220 model

Set

2

9

excavator

power not less than 260hp,3 capacity of hopper not less than 4.3m and 9.2m of cantilever

Set

1

wear

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4.5.3


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Coal screening and crushing equipments No.

Description

Model & code

Unit

Q'ty

Ring hammer coal crusher

HCSZ-1000 model, output Q=1000t/h, with monitor panel for measurement of temperature and vibration and hydraulic startup unit; granule of outlet coal≤30mm, power of motor 550kW and 6kV

Set

2

2

roller screen

Capacity 1250t/h with motor and bypass unit, retarder, control casing, steel hopper and elbow guard; granule of inlet coal≤300mm and granule of outlet coal ≤30mm

Set

2

3

wear dredge pump

Flow Q＝15m3/h；head 25m；power 7.5kW, 380V

Set

1

4

Buffer air lock

900×900mm, applicable belt width 1200mm

Set

4

1

4.5.4

Rem arks

Belt conveyor system No.

Description

Model & code

Unit

Q'ty

1

C-0Abelt conveyor

B=1200mm, V=3.5m/s, Q=1250t/h, L=202.87m, h=12.115m; motor 185kW, 6kV; rubber belt EP200-4 non-flammable belt

Set

1

2

C-1Abelt conveyor

B=1200mm, V=3.5m/s, Q=1250t/h, L=202.87m, h=12.115m; motor 185kW, 6kV; rubber belt EP200-4 non-flammable belt

Set

1

3

C-2Abelt conveyor

B=1200mm,V=3.5m/s,Q=1250t/h, L=125.3m, h=14.415m; motor 185kW, 6kV; rubber belt EP200-4 non-flammable belt

Set

1

4

C-3belt conveyor

B=1200mm, V=3.5m/s, Q=1250t/h, L= 350.90m,h=12m; motor 250kW, 6kV; rubber belt ST800 non-flammable belt

Set

1

5

C-4A/B conveyor

belt

B=1200mm, V=3.5m/s, Q=1250t/h, LA=90.6m,LB=84.6m, h=21.415m; motor 200kW, 6kV; rubber belt EP200-4 non-flammable belt

Set

2

6

C-5A/B conveyor

belt

B=1200mm, V=3.5m/s, Q=1250t/h, LA=LB=196.8m,h=46.215m; motor 400kW, 6kV。EP300-5 non-flammable belt

Set

2

7

C-6A/B conveyor

belt

B=1400mm, V=2.5m/s, Q=1250t/h, LA=LB=138.85m, h=0m; motor 110kW, 0.38kV; rubber belt ST630 non-flammable belt

Set

2

8

C-7belt conveyor

B=1200mm, V=3.5m/s, Q=1250t/h, L=81.7m, h=14m; motor 160kW, 6kV; rubber belt ST630 non-flammable belt

Set

1

9

mechanical sampler

CCYZ-12 model, applicable belt width 1200mm, installed total power 30kw

Set

3

coal

Rem arks



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10

electronic weighing unit

belt

ICS-17A-1200 model, applicable belt width 1200mm, 35° of pulley chute angle, with wall hanging indicator & weights-hoist calibration unit, accumulated allowance ≤±0.5%, calibration accuracy ±0.25%, operation accuracy ±0.5% and range of weighing 50～1250t/h

11

Electric two-side plough tripper

DTII04F11 model, variable chute angle, applicable for belt width of B1400mm, with a hopper and swing gate

Set

18

12

cantilever electromagnetic separator

B=1200mm self provided trolley traveling mechanism with program controlled cabinet and applicable for belt width of B=1200mm

Set

4

13

Disc electromagnetic separator

RCDB-12 model, self provided trolley traveling mechanism with program controlled cabinet and applicable for belt width of B=1200mm

Set

2

14

electric baffle three way pipe

900×900mm,60° with electric push lever and applicable for belt width of 1200mm

Set

4

15

Submerge dredge pump

Flow Q ＝ 15m3/h ； head 25m ； power 7.5kW, 380V

Set

6

16

vibration coal feeder

Rated capacity 500t/h

Set

2

17

Hydraulic auto tightening unit

DYL-04-1/10model, model with local control casing, 4kW power of motor in hydraulic pump station and allowing local and remote control

Set

2

4.5.5

wear

Set

3

Control System No.

Description

Model & codec

Unit

Q'ty

1

Speed monitor

JSBHDJ-II model

Set

10

2

two-step off tracking switch

KPP-12-30 model

Set

21

3

two-direction switch

KLS-III model

Set

50

4

high charge level meter

L2000C model

Set

20

5

low charge level meter

L2000C model

Set

10

6

ultra wave level meter

XPL model

Set

10

7

close unit

JZF-6 model trigger vibration power 250kg and power of 0.4kW

Set

10

8

coal blocking detector

LDB-X model

Set

10

9

metal detector

Applicable belt width1200mm

Set

2

string-pulling

preventative

vibration

5.

Tools, Instrument for Commissioning

5.1

Walkie talkie;

5.2

Handheld vibration meter;

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5.3 c

Digital multimeter;

5.4

Handheld thermodetector;

5.5

Tachometer.

6.

Prerequisite for Commissioning Before formally beginning system commissioning, commissioning persons should conduct comprehensive conditions on conditions that should be available for commissioning of this system according to contents listed in Appendix 1 (Commissioning condition list) and make well the records.

6.1

Installation of the system is completed with complete record.

6.2

The inside of system and equipments is cleaned and it is ensured that there is no foreign matter.

6.3

The marks of equipments are completed and correct.

6.4

Site work condition shall be that the access is free, illumination enough and emergency lighting available.

6.5

The communication equipments are available.

6.6

The fire fighting materials are enough and easy to get and use.

6.7

The maintenance tools and materials are completed and enough.

6.8

The operation tools and record formats are ready.

6.9

The commissioning tools, instruments and equipments are ready.

6.10

The commissioning of cooling water system is satisfactory and can be put into operation.

6.11

The oil quality of hydraulic oil system is qualified and operation of oil pump is normal.

6.12

Single equipment commissioning in the system is qualified and action reliable.

6.13

The tests for all protection interlock and signal units are qualified.

6.14

Power supply for equipments is reliable.

6.15

All meters and indicators in the system are complete and calibration is qualified.

6.16

Electrical test for motors is satisfactory and running idle for 2h with good condition.

7.

Measures for Commissioning Organization This procedure shall be executed under the organization of commissioning contractor. The construction contractors shall cooperate closely with each other according to their respective work responsibilities so as to guarantee safe and effective implementation of commissioning. The division of works is as follows::

7.1

Responsibilities of Commissioning Contractor ◆

Preparation and revision of commissioning procedures;

◆

Preparation of commissioning plan;

◆

Preparation of instruments and equipment required for commissioning;


7.2

7.3

7.5

7.6

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◆

Hold technical disclosure meeting for commissioning;

◆

Organize the commissioning work to be carried out by various parties;

◆

Give instructions to operators in the operation;

◆

Prepare commissioning report.


be responsible for individual commissioning of equipment and provide relevant record and certificate of commissioning;

◆

be responsible for inspection, maintenance and defect elimination of equipment under commissioning;

◆


◆

Assist the commissioning contractor in the commissioning of subsystems;

◆

be responsible for temporary coordination of local control and instruments, terminals.

Responsibilities of Equipment Manufacturers ◆

7.4


Representative of manufacturer, if present on the site offering service, shall provide technical assistance during equipment commissioning.

Responsibilities of Plant Operator ◆

Prepare tools to be involved in operation;

◆

Prepare operation log and forms;

◆

Operate the system and equipment according to the operating procedures and the instructions of the commissioning personnel;

◆

be responsible for patrol inspection, condition and normal maintenance of system and equipment;

◆

be responsible for dealing with the accidents occurred in commissioning。

Responsibilities of Dongfang Electric ◆

be responsible for supervision and control over commissioning work;

◆

Coordinate with commissioning contractor, the Owner, and other contractors in the commissioning;

◆

Participate in and witness the commissioning work;

◆

Organize analysis and settlement of major technical issues in commissioning.

Responsibilities of Owner ◆

Supervise the execution of commissioning procedures;

◆

Witness the commissioning work;

◆

Accept the results of commissioning.



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8.


8.1

Check and accept the electric three-way baffle and keep the following data: Condition if KKS code, designation and local position indication is correct, if the remote operation direction and dback is satisfactory, valve open (close) time, test date and signature by person in charge of test. Refer to Appendix 4 for detail.

8.2

Interlock Protection and Alarms Condition (Note: the result of logic discussion will prevail for the item of interlock protection tests);

8.2.1

Place the equipment power supply to test position;

8.2.2

Check the items below:

8.2.2.1

Startup equipment from a computer and feedback on the computer is correct;

8.2.2.2

Shutdown equipment from a computer and feedback on the computer is correct;

8.2.3

Test for single unit local control and emergency buttons. Check all sections of the belt and CHP equipments and start a single equipment by means of local control or manual unlock (a way for test the equipment) when condition is provided and stop the equipment immediately by emergency button or emergency shutdown string-pulling switch to check for correct rotation direction and good condition of emergency button.

8.2.4

Test for interlock protection of the equipment (Note: the result of logic discussion will prevail for the item of interlock protection tests)

8.2.4.1

Belt conveyor and accessory equipment

(1)

Belt Conveyor A (B), check for condition of start and trip

No.

Test item

C-0Abelt conveyor startup condition (1)

At remote location

(2)

No belt conveyor integrated failure signal

(3)

flow selection C-1Abelt conveyor already in operation

Tripping alarm condition for C-0A belt conveyor (1)

over current protection action of electrical

(2)

20s delay for skid

(3)

5s delay for off tracking

(4)

12s delay for coal blocking

(5)

string-pulling witch action

(6)

high temperature of A phase coil of motor (one of any eight points)

(7)

flow selection C-1Abelt conveyor operation shutdown


At remote location

(2)


(3)

flow selection C-2Abelt conveyor already in

Fixed value

Results

Remarks



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operation Tripping alarm condition for C-1A belt conveyor (1)


(2)

20s delay for skid

(3)


(4)


(5)


(6)


(7)

flow selection C-2Abelt conveyor operation shutdown

C-2A belt conveyor startup condition (1)

At remote location

(2)


(3)

flow selection C-3belt conveyor in operation

Tripping alarm condition for C-2Abelt conveyor (1)


(2)

20s delay for skid

(3)


(4)


(5)


(6)


(7)

flow selection C-3belt conveyor after operation, operation shutdown

C-3belt conveyor startup condition (1)

At remote location

(2)


(3)

Flow from dock to #1 coal yard, 1#stacker reclaimer (stacking) already in operation；flow from #1 coal yard to coal bunker, C-4Abelt conveyor already in operation or C-4Bbelt conveyor already in operation；flow from dock to coal bunker, C-4Abelt conveyor already in operation or C-4Bbelt conveyor already in operation；(or)

Tripping alarm condition for C-3belt conveyor (1)


(2)

20s delay for skid

(3)


(4)


(5)




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(6)


(7)

Flow from dock to #1 coal yard, 1# stacker reclaimer (stacking) operation shutdown；flow from #1coal yard to coal bunker, C-4Abelt conveyor operation shutdown or C-4Bbelt conveyor operation shutdown；flow from dock to coal bunker, C-4 Abelt conveyor shutdown or C-4B belt conveyor shutdown ；

C-7belt conveyor startup condition (1)

At remote location

(2)


(3)

Flow from emergency ground hopper bunker ,C-4Abelt conveyor already in operation

to

Tripping alarm condition for C-7belt conveyor (1)


(2)

20s delay for skid

(3)


(4)


(5)


(6)


(7)

Flow from emergency ground hopper to bunker, C-4Abelt conveyor operation shutdown


At remote location

(2)


(3)

C-5Abelt conveyor in operation



(2)

20s delay for skid

(3)


(4)


(5)


(6)


(7) (8)

roller screen A operation shutdown C-5Abelt conveyor operation shutdown

C-4Bbelt conveyor startup condition (1)

At remote location

(2)



(3)


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C-5Bbelt conveyor in operation

C-4Bbelt conveyor tripping at cantilever condition (1)


(2)

20s delay for skid

(3)


(4)


(5)


(6)


(7)

roller screen B operation shutdown

(8)

C-5Bbelt conveyor operation shutdown


At remote location

(2)

No integrated failure signal

(3)

C-6Abelt conveyor in operation or C-6Bbelt conveyor in operation



(2)

20s delay for skid

(3)


(4)


(5)


(6)


(7)

C-6A belt conveyor operation shutdown or C-6B belt conveyor operation shutdown


At remote location

(2)


(3)

C-6B belt conveyor in operation or C-6A belt conveyor in operation

Tripping alarm condition for C-5Bbelt conveyor (1)


(2)

20s delay for skid

(3)


(4)


(5)


(6)




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(7)

startup selection C-6B belt conveyor after operation shutdown

(8)

flow selection C-6A belt conveyor after operation shutdown

C-6A belt conveyor startup condition (1)

At remote location

(2)




(2)

20s delay for skid

(3)


(4)


(5)


(6)



At remote location

(2)


Tripping alarm condition for C-6Bbelt conveyor (1)


(2)

20s delay for skid

(3)


(4)


(5)


(6)


ship unloading machine A startup condition (1)

At remote location

(2)


(3)


Tripping alarm condition for ship unloading machine A (1)

electrical protection action

(2)

C-0Abelt conveyor operation shutdown

ship unloading machine B startup condition (1) (2) (3)

At remote location No integrated failure signal C-0Abelt conveyor in operation

Tripping alarm condition for ship unloading machine B



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(1)


(2)

C-0Abelt conveyor operation shutdown

(2)

Check for interlock shutdown condition of accessory equipment of belt conveyor No.

Test item

Fixed value

TT-0 belt electromagnetic separator A interlock startup condition (1)

C-0A belt conveyor in operation

TT-0 belt electromagnetic separator A interlock shutdown condition (1)

C-0A belt conveyor shutdown

TT-0 impulsive bag dust separator A interlock startup condition (1)


TT-0 impulsive bag dust separator A interlock shutdown (1)

C-0Abelt conveyor shutdown

TT-0 spray dust suppression unit A interlock startup condition (1)


TT-0 spray dust suppression unit A interlock shutdown (1)


C-0A Belt A side vibration close protection unit A interlock startup condition (1)

C-0A belt conveyor in operation and C-1A belt conveyor in operation

(2)

Coal block up

C-0A Belt A side vibration close protection unit A interlock shutdown condition (1)

C-0A belt conveyor operation shutdown and C-1A belt conveyor operation shutdown delay for 2s





TT-1 belt electromagnetic separator B interlock startup condition (1)


TT-1 belt electromagnetic separator B interlock shutdown conditon (1)

C-1Bbelt conveyor shutdown

TT-1 impulsive bag dust separator A interlock startup condition (1)


TT-1 impulsive bag dust separator A interlock shutdown condition (1)


TT-1 spray dust suppression unit A interlock startup condition

Results

Remarks


(1)


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Page 15 of 40


TT-1 spray dust suppression unit A interlock shutdown condition (1)


C-1A Belt A side vibration close prevention unit interlock startup condition (1)

C-1A belt conveyor in operation and C-2A belt conveyor in operation

(2)

Coal block up

C-1A Belt A side vibration close prevention unit A interlock shutdown condition (1)

C-1Abelt conveyor operation shutdown and C-2Abelt conveyor operation shutdown delay for 2s

TT-2 impulsive bag dust separator interlock startup condition (1)


TT-2 impulsive bag dust separator interlock shutdown condition (1)


TT-2 spray dust suppression unit interlock startup condition (1)




Sampler for coal entering the plant A interlock startup condition (1)


Sampler for coal entering the plant A interlock shutdown condition (1)

C-1Abelt conveyor operation shutdown delay for 60s

Roller screen A pull lever interlock startup condition (1)

roller screen A operation shutdown

(2)

electrical failure

(3)

transfer blocking failure

Roller screen A heater interlock startup condition (1)

roller screen A in operation

Roller screen A heater interlock shutdown condition (1)


(2)

electrical failure

(3)


Roller screen B pull lever interlock startup condition (1)

roller screen B operation shutdown

(2)

electrical failure

(3)


Roller screen B heater interlock startup condition


(1)


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roller screen A in operation

Roller screen B heater interlock shutdown condition (1)


(2)

electrical failure

(3)


Impulsive bag dust separator in coal crusher house A interlock startup condition (1)


Impulsive bag dust separator in coal crusher house A interlock shutdown condition (1)

C-4Abelt conveyor shutdown delay for 60s

Impulsive bag dust separator in coal crusher house B interlock startup condition (1)

C-4B belt conveyor in operation

Impulsive bag dust separator in coal crusher house B interlock shutdown condition (1)

C-4B belt conveyor shutdown delay for 60s

Coal crusher house spray dust suppression unit A interlock startup condition (1)


Coal crusher house spray dust suppression unit A interlock shutdown condition (1)


Coal crusher house spray dust suppression unit B interlock startup condition (1)


Coal crusher house spray dust suppression unit B interlock shutdown condition (1)

C-5B belt conveyor shutdown

Coal crusher house outside metal detector A interlock startup condition (1)


Coal crusher house outside metal detector A interlock shutdown condition (1)

C-5Abelt conveyor shutdown delay for 60s

Coal crusher house outside metal detector B interlock startup condition (1)


Coal crusher house outside metal detector B interlock shutdown condition (1)

C-5B belt conveyor shutdown delay for 60s

Coal crusher house outside disc electromagnetic separator A interlock startup condition (1)

C-5Abelt conveyor in operation and conveyor in operation

C-4Abelt

Coal crusher house disc electromagnetic separator A interlock shutdown condition (1)

C-5Abelt conveyor shutdown and conveyor shutdown

C-4Abelt

Coal crusher house outside disc electromagnetic separator B interlock startup condition (1)

C-5Bbelt conveyor in operation and conveyor in operation

C-4Bbelt



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Coal crusher house disc electromagnetic separator B interlock shutdown condition (1)

C-5Bbelt conveyor shutdown and C-4Bbelt conveyor shutdown

Coal crusher house vibration close prevention unit B interlock startup condition (1)

C-5Bbelt conveyor in operation and C-4Bbelt conveyor in operation

(2)

Coal block up

Coal crusher house vibration close prevention unit A interlock startup condition (1)

C-5Abelt conveyor in operation and C-4Abelt conveyor in operation

(2)

Coal block up

Coal crusher house vibration close prevention unit D interlock shutdown condition (1)

C-5A belt conveyor operation shutdown and C-4A belt conveyor operation shutdown delay for 2s

Coal crusher house vibration close prevention unit B interlock shutdown condition (1)

C-5Bbelt conveyor operation shutdown and C-4Bbelt conveyor operation shutdown delay for 2s

Coal crusher house vibration close prevention unit C interlock startup condition (1)


(2)

Coal block up



Coal crusher house vibration close prevention unit D interlock startup condition (1)


(2)

Coal block up


C-5B belt conveyor operation shutdown and C-4B belt conveyor operation shutdown delay for 2s

C-5A Belt electromagnetic separator (1)

C-5Abelt conveyor in operation, interlock startup belt electromagnetic separator

(2)

C-5Abelt conveyor operation shutdown, interlock shutdown belt electromagnetic separator

Sampler for coal as fired A interlock startup condition (1)


Sampler for coal as fired A interlock shutdown (1)

C-5Abelt for 60S

conveyor

operation

shutdown

Sampler for coal as fired B interlock startup condition

delay


(1)


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Sampler for coal as fired B interlock shutdown (1)

C-5B belt conveyor operation shutdown delay for 60S

C-5A Belt A side vibration close prevention unit interlock startup condition (1)

C-5A belt conveyor in operation and conveyor in operation

(2)

Coal block up

C-6Abelt

C-5A Belt A side vibration close prevention unit interlock shutdown condition (1)


C-5A Belt B side vibration close prevention unit interlock startup condition (1)

C-5Abelt conveyor in operation and C-6Bbelt conveyor in operation

(2)

Coal block up

C-5A Belt B side vibration close prevention unit interlock shutdown condition (1)

C-5Abelt conveyor operation shutdown and C-6Bbelt conveyor operation shutdown delay 2s

for

C-5BBelt A side vibration close prevention unit interlock startup condition (1)

C-5Bbelt conveyor in operation and C-6Abelt conveyor in operation

(2)

Coal block up

C-5B Belt A side vibration close prevention unit interlock shutdown condition (1)

C-5Bbelt conveyor operation shutdown and C-6Abelt conveyor operation shutdown delay for 2s

C-5B Belt B side vibration close prevention unit interlock startup condition (1)


(2)

Coal block up

C-5B Belt B side vibration close prevention unit interlock shutdown condition (1)



C-3belt conveyor in operation and conveyor in operation

C-4Abelt


C-3belt conveyor shutdown and C-4Abelt conveyor shutdown

TT-3 impulsive bag dust separator A interlock startup condition


(1)


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C-3belt conveyor in operation

TT-3 impulsive bag dust separator A interlock shutdown condition (1)

C-3 belt conveyor shutdown

TT-3 impulsive bag dust separator B interlock startup condition (1)

C-3 belt conveyor in operation

TT-3 impulsive bag dust separator B interlock shutdown condition (1)

C-3 belt conveyor shutdown

TT-3 spray dust suppression unit A interlock startup condition (1)



C-3belt conveyor shutdown

TT-3 spray dust suppression unit B interlock startup condition (1)


TT-3 spray dust suppression unit B interlock shutdown condition (1)

C-3belt conveyor shutdown

Coal bunker room TT belt electromagnetic separator A interlock startup condition (1)


Coal bunker room TT belt electromagnetic separator A interlock shutdown condition (1)


Coal bunker room TT belt electromagnetic separator B interlock startup condition (1)


Coal bunker room TT belt electromagnetic separator B interlock shutdown condition (1)

C-5B belt conveyor shutdown

Coal bunker room TT impulsive bag dust separator A interlock startup condition (1)


Coal bunker room TT impulsive bag dust separator A interlock shutdown condition (1)


Coal bunker room TT impulsive bag dust separator B interlock startup condition (1)


Coal bunker room TT Impulsive bag dust separator B interlock shutdown condition (1)


Coal bunker room TT Spray dust suppression unit A interlock startup condition (1)


Coal bunker room TT Spray dust suppression unit A interlock shutdown condition (1)


Coal bunker room TT Spray dust suppression unit B interlock startup condition


(1)


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Coal bunker room TT Spray dust suppression unit B interlock shutdown condition (1)


(3) Roller screen A(B)

startup tripping

No.

condition

check

Test item

Fixed value

Results

Remarks

Results

Remarks

roller screen A startup condition (1)

At remote location

c

(2)


(3)


roller screen A tripping alarm condition (1)

electrical failure

(2)


(3)

Action of emergency button

(4)


roller screen B startup condition (1)

At remote location

(2)


(3)


roller screen B tripping alarm condition (1)

electrical failure

(2)


(3)


(4)


(4) ring hammer coal crusher A(B)

No.

startup tripping

Test item

condition

check

Fixed value

ring hammer coal crusher A startup condition (1)

At remote location

(2)


(3)

C-5Abelt conveyor in operation and C-4Abelt

c



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conveyor in operation ring hammer coal crusher A tripping alarm condition (1)


(2)

high vibration in left bearing, alarm delay for 3s

(3)

high vibration in right bearing, alarm delay for 3s

(4)

high temperature in left bearing, alarm delay for 3s

(5)

high temperature in right bearing, alarm delay for 3s

(6)


(7)

C-5Abelt conveyor in operation and C-4Abelt conveyor shutdown

ring hammer coal crusher B startup condition (1)

At remote location

(2)


(3)


ring hammer coal crusher B tripping alarm condition (1)


(2)

high vibration in left bearing, alarm delay for 3s

(3)

high vibration in right bearing, alarm delay for 3s

(4)

high temperature in left bearing, alarm delay for 3s

(5)

high temperature in right bearing, alarm delay for 3s

(6)


(7)

C-5Bbelt conveyor in operation and C-4Bbelt conveyor shutdown

(5) stacker reclaimer

startup tripping

No.

condition

check

Test item

stacker reclaimer

startup condition

(1)

At remote location

(2)


(3)

C-3belt conveyor in operation when reclaiming coal or request stacker reclaimer in operation when stacking coal

stacker reclaimer

Fixed value

tripping alarm condition

(1)


(2)

C-3belt conveyor operation shutdown when reclaiming coal or request stacker reclaimer in shutdown condition when stacking coal

c

Results

Remarks



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(6) Vibration coal feeder A (B) startup tripping No.

condition check

Test item

Fixed value

Results

Remarks

Vibration coal feeder A startup condition (1)

Programmed control allowed for coal feeder

(2)

No electrical failure

(3)


Vibration coal feeder A tripping alarm condition (1)

electrical failure

(2)

C-7belt conveyor operation shutdown

Vibration coal feeder B startup condition (1)

Programmed control allowed for coal feeder

(2)

No electrical failure

(3)


Vibration coal feeder B tripping alarm condition (1)

electrical failure

(2)

C-7belt conveyor operation shutdown

8.2.5

CHP interlock

8.2.5.1

If the upstream equipment, reverse coal flow of this equipment, startup is done, the system will startup automatically when the system is in auto.

8.2.5.2

The equipment will be shut down immediately and equipments in the emergency flow of the system also will be shut down immediately (except the crusher and screen will delay fro 5s) if this equipment is failed or a downstream equipment, in the same direction as of coal flow of this equipment, is failed.

8.2.5.3

The three-way baffle expansion head will in operation after the operator gives order of pre-startup order of the flow after the operation has made the flow selection.

8.2.5.4

The electric three-way baffle and the belt conveyor expansion heads can only switch the unit position in the state of belt conveyor shutdown and belt conveyor interlocked with the upstream belt conveyor.

8.2.5.5

The magnetic separator will start up with the corresponding belt conveyor at the same time but delay in shutdown.

8.2.5.6

The magnetic separator will start up with the corresponding belt conveyor in interlock and the startup will be in advance and delay in shutdown.

8.2.5.7

The lifting up and lowering down of the plough tripper is interlocked with coal level of coal bunker, the plough tripper in maintenance bunker and full level coal bunker is kept lifting up and the plough tripper in the rear bunker is kept lowering down.

8.2.5.8

The stacker reclaimer is interlocked with C-3belt conveyor (under the precondition of having person signal of stacking or reclaiming operation)

8.2.6

Test for system interlock

8.2.6.1

Startup interlock: In case of starting up the system, the startup begins in sequence from the



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last belt conveyor to the first belt conveyor, in the refluent direction of coal flow and then start to feed coal. 8.2.6.2

Shutdown interlock: When the operation requires to shutdown, the coal supply shall stopped first. And then shutdown the conveyor from first to last in the same direction as coal flow. Each belt conveyor will be delayed to shutdown as per set time between them, i.e. it is required that the remained coal on the front belt conveyor finished and the stop its operation.

8.2.6.3

Emergency interlock：

8.2.6.4

In operation, if there is a grave accident in any of equipments, the equipment refluent to the coal flow will trip in interlock immediately, except the crusher which will trip in delay if it is not an accident of the crusher.

When the emergency shutdown button is pressed, the equipments in operation will shutdown totally, except the crusher and screen which will be shutdown in delay.

Use of interlock:

The action of interlock is allowed by means of the signal sent by relay in the interlock loop. Therefore, in any of operation ways, the interlock position shall be correctly put in service for all operation equipments, otherwise, the interlock will not act.

The in-service position of all interlock switch shall be consistent with the operation way of the system.

When single equipment is trial run, the interlock of the equipment is released.

8.2.6.5

For tests of actual program control startup and shutdown and system interlock, refer to Appendix 5.

8.3

CHP startup and shutdown

8.3.1

Check before startup

8.3.1.1

Ground of coal storage yard shall be level, drain free and illumination enough.

8.3.1.2

The installation of stacker reclaimer shall be as per requirement of construction and acceptance regulations. The requirements include the following, but not limited to: ◆

The lead sealing of hydraulic pressure equipments and elements shall be complete and no damage; the lubricant and hydraulic system are cleaned, pressure test qualified and all the hydraulic pressure equipments and elements shall work normally without leakage during trial run.

◆

The pitching hydraulic oil cylinders on both sides of the gate column shall be parallel and vertical to the horizontal level. The rise and fall of the two hydraulic cylinder piston link shall be synchronized and the level of rise and fall consistent.

◆

Check for that the speed of bucket wheel conforms to the regulation, belt working normal without skid or off tracking and the feed belt coal chute shall be at the same concentricity with the rotor plate. The contact of all wheels with rail shall be proper, work of the rail clamping device normal and reading of indicator correct.

8.3.1.3

The installation of coal unloading trench, ground coal bunker and rail shall meet the requirement of the acceptant regulations and the illumination inside shall be enough and explosive proof type.

8.3.1.4

The work of coal unloading spray dust suppression device is normal.

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure 8.3.1.5


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The installation of all coal handling belt of coal conveyors is completed and conforms to the construction acceptant regulations, include but not limited to the following requirements: ◆

There shall be no hardening, chapping, wearing or friction on the rubber surface of the belt. The operation shall be smooth and the off tracking shall not be beyond the edge of the pulley.

◆

The connection between the pulley support and frame shall be fast, the bearing of pulley shall insert the groove of support fast and the surface of pulley smooth and without burr. The lubrication of the pulley is normal and rotation free.

◆

The axial line of pulley must be vertical to the belt. The elevation of all frame and non-smooth shall conform to the regulations.

◆

The fastening device at the rear shall be free, the sliding surface and rod shall be straight and well lubricated. The vertical fastening device is parallel with the slide way, rise and fall free and there shall be protection guard plate at the turning of the belt to prevent metal material from falling in.

◆

The placement of balance block shall be reliable. The balance shall be proper and when skids in coal feeding shall increase. The work of tightening device shall be normal when the belt is started or shut down and the belt will not skid.

◆

The commissioning of belt tightening device and the hydraulic device is completed and can be put into service.

◆

The commissioning of belt expansion device is completed and can be put into service.

◆

The coal guide chute shall be parallel to the belt, center aligned and the contact at the seal is smooth.

◆

The interlock with all section emergency buttons is in proper state. The room illumination is enough, the installation of the ventilation and dust proof unit is completed. The work of switch coal baffle is free and tight.

8.3.1.6

The installation of the crusher and screen is completed, all parts are fast and reliable, rotation free, the foundation bolts are connected fast and the idle run is qualified.

8.3.1.7

The installation angel, magnetic surface and distance between the belts of the electromagnetic separator shall conform to the design and the hanging shall be reliable.

8.3.1.8

The installation of the plough tripper is completed with free operation and correct position of movement weight.

8.3.1.9

The inside of coal bunker is clean without foreign matters and leakage from anywhere of the seal.

8.3.1.10

the electronic weighing unit is cleaned without accumulated coal or dust and the calibration is qualified and it can be put into service.

8.3.1.11

all kinds of instruments in the coal control room shall be completed, light alarm is good and the illumination and communication equipment are completed and ready.

8.3.2

Tests for system idle startup and interlock Check for all sections of belt conveyors and coal handling equipments and after the condition is available, startup all equipments as per sequence by means of program control auto or manual interlock. After ensuring that the operation is normal, shutdown the rear belt conveyor or any equipment or belt conveyor in the system, the other upstream equipments or belt conveyors shall shutdown in sequence and the alarm signal is sent.



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The test for system interlock will be carried out as per five operation modes below and all equipments will startup as per sequence.

ship unloading machine→coal bunker

ship unloading machine →stacker reclaimer →coal yard

ship unloading machine →emergency→coal yard

stacker reclaimer coal yard——coal bunker emergency hopper→coal bunker For detail, refer to Appendix 5 8.3.3

Check for iron attraction of the electromagnetic separator After completion of installation and commissioning of the electromagnetic separator, the iron attraction of the electromagnetic separator can be carried out. In the test, different shape and weight of iron pieces is placed on the belt and then put the electromagnetic separator into service. Observe the iron attraction and repeat the test many times, record the result and count the rate of iron attraction. If failure of iron attraction is found, the cause shall be found out. All the iron pieces on the belt shall be removed after the test is completed.

8.3.4

Test for idle run of CHP and coalfeeding. Five operation modes of CHP idle operation can be carried out after the check and test of all kinds of startups are normal. The coalfeeding test can be carried out when the boiler house raw coal hopper is ready for coalfeeding.

8.3.5

Other auxiliary system and equipments in service (1)

Vibration coal feeder

(2)

Electric plough tripper

(3)

Mechanical sampler

(4)

Dust separator

(5)

Electronic belt weighing unit

(6)

Sewage purification and flushing water supply equipment

8.3.6

Put the system into operation

8.3.6.1

Programm control auto control means (1)

The selected coalfeeding mode is “Program control” by the control station and press “reset” to make the program in initial state.

(2)

Select flow selection in the control station as per coal flow direction, verify the Flow valid and the flows are per operation modes:

ship unloading machine→coal bunker ship unloading machine →stacker reclaimer →coal yard ship unloading machine →emergency→coal yard stacker reclaimer →s coal yard——coal bunker



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emergency ground hopper→coal bunker

8.3.6.2

8.3.6.3

(3)

Press “Pre-startup” button on “the total flow chart” in the control station to check for correct position of all plough trippers and confirm that the system startup is permitted.

(4)

Press “Program startup” to start all equipments in the system as per flow selected.

(5)

In the process of program startup, if any equipment is failed the process of program startup is terminated. After the problem is removed, press “Reset”, “Pre-startup” and “program startup” buttons, the program startup process will start from the equipment where the failure occur.

(6)

When it is in program control auto shutdown, press “Program shutdown” button and select coal source and after “Confirmation”, the equipment in operation will automatically shutdown with delay as per flow direction of coal from the place where the coal source is.

Interlock manual control mode (1)

The “Interlock” of coalfeeding mode is selected in the control station and press “Reset” and “distribution and reset” buttons to make the program initial state.

(2)

Select the flow as per coal flow direction in the control station and confirm that “Flow is valid”.

(3)

Check for correct position of the plough tripper and baffle by manual operation in the “Total flow chart” at the control station.

(4)

Startup all equipments in the Flow at “Inquiry of control and status” window of each equipment as per refluent coal flow direction.

(5)

During startup, if accident occurs, eliminate the failure and then press “Reset” button and manually initiate startup process at the place where the equipment failed.

(6)

In normal shutdown, shutdown in sequence the equipments in the Flow at “Inquiry of control and status” window of each equipment as per the same direction of coal flow direction.

Mode of coal distribution (1)

(2) 8.4

Program coal distribution ◆

”Program coal distribution” is selected in the control station and press “Distribution reset” button to make the coal distribution program in an initial state.

◆

Press “Pre-startup” button at the control station to check for the fall down position of the rear plough tripper and the rest in rise up position.

◆

When the belt conveyor is already in operation, the program will start the automatically coal distribution evenly with the priority as per low coal level to high coal level and the balance.

◆

The program coal distribution is completed when all coal bunkers have distributed to high coal level, the system starts to shutdown in delay all equipments as per coal source sequence.

When it is in manual coal distribution, the selected coal distribution mode is “Manual distribution” and distributes coal with manual operation of all plough trippers.

System Operation during Integral Startup



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The reliability of the system operation is tested as per non-load phase, load phase, full load phase and 30 days relciability operation phase. (1)

Dynamic regulation of system: in the process of system in service and especially running with load, the monitor of the equipment shall be strengthened to ensure that the system is in the best state.

(2)

Complete trial operation record: for the main parameters in the trial run startup, refer to Appendix 2 and 3.

9.

Safety Measures

9.1


9.1.1

The parties participating in commissioning shall be familiar with and abide by the relevant safety rules, wear reasonable clothing and appropriate personal protective equipments.

9.1.2


9.1.3


9.1.4

All professional shall be on respective duties during the whole commissioning to guarantee the safe operation of equipments.

9.2


9.2.1

Injuries might be caused by rotating equipment during commissioning or test. Therefore, special care must be taken during work and do not touch the rotating components with tools or your hand.

9.2.2

The complete and fast protection railing shall be installed on both sides of belt conveyors.

9.2.3

In the period of commissioning, the ground building ventilation facilities shall be put in service and the emergency exit free.

9.2.4

During system startup and interlock test, special person shall be deployed to monitor and check all the equipments and belts. The communication contact shall be kept. Any situation shall be reported in time and all the operation shall be directed in unification.

9.3


9.3.1

When the position of head expansion device is switched over, the belt conveyor must be started up in idle state first and then switch over the position.

9.3.2

The eye striking sign shall be provided at the cross place between the edge of coal yard and surface place of tunnel to prevent the top of tunnel from damaging by bulldozer.

9.3.3

If any risk situation occurs during the equipment operation, the equipment can be shut down by “Emergency shutdown” button.

9.3.4

If the stopped flow has common equipments with other flow, the mode of “Program shutdown cannot be used. The mode of manual interlock is used to shutdown in sequence the equipment to the place where it is across with other flow.

10.

Appendix



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Appendix 1 Commissioning Condition Check-list No.

Items

Requirements

Result

1

System installation

installation completed with complete record

□Yes □No

2

Inside system and equipment

Cleaned and no foreign matters

□Yes □No

3

Equipment markings

Marking complete and correct

□Yes □No

4

Field condition

Access free, illumination enough and emergency illumination available

□Yes □No

5


available

□Yes □No

6

Fire apparatus


□Yes □No

7


Complete and enough

□Yes □No

8

operation tools and record formats

Prepared

□Yes □No

9

Commissioning tools and instruments

Prepared

□Yes □No

10

Cooling water system

commissioning satisfactory and can be put into operation

□Yes □No

11

Hydraulic oil system

Oil quality qualified and oil pump operation normal

□Yes □No

12

Equipments in system

Single equipment commissioning satisfactory and action reliable

□Yes □No

13

All protection interlock and signal unit

Test eligible

□Yes □No

14

Power supply

Reliable

□Yes □No

15

All kinds of meters and gauges in the system

Complete and satisfactory in calibration

□Yes □No

16


Test is qualified and having 2h idle operation and condition is good.

□Yes □No


Date: Date:

Date:


Dongfang Electric:

Date:

Remarks

Date:



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Appendix 2 CHP equipment operation record format No.

Item

Unit

C-0A belt conveyor 00EAC11AF000

A


A


A

C-3 belt conveyor 00EAC11AF003

A

C-7 belt conveyor 00EAC11AF007

A


A

C-4B belt conveyor 00EAC12AF004

A


A

C-5BA belt conveyor 00EAC12AF005

A


A

C-6B belt conveyor 00EAC12AF006

A

1#stacker reclaimer 00EAF11AF001

A

A ring hammer coal crusher 00EBC11AJ001

A

Bring hammer coal crusher 00EBC12AJ001

A

A roller screen 00EBD11AT001

A

B roller screen 00EBD12AT001

A

17

Vibration coal feeder 00EAB11AF001

A

18

Vibration coal feeder 00EAB11AF002

A


Date: Date:

Date:

startup

shutdown


Date: Date:

Remarks



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Appendix 3 Trial Run Record Format of CHP No.

Items

1

C-0Abelt conveyor 00EAC11AF000

2


3


4

C-3belt conveyor 00EAC11AF003

5

C-7belt conveyor 00EAC11AF007

6


7

C-4Bbelt conveyor 00EAC12AF004

8


9

C-5BAbelt conveyor00EAC12AF005

10


11

C-6Bbelt conveyor 00EAC12AF006

12

1#stacker reclaimer 00EAF11AF001

13

Belt electromagnetic separator 00EBE11AT101

14


15


16


17


18

Disc electromagnetic separator 00EBE11AT401

19

Disc electromagnetic separator 00EBE12AT401

20

metal detector 00EBE11AT402

21

metal detector 00EBE12AT402

22

A ring hammer coal crusher 00EBC11AJ001

23

B ring hammer coal crusher 00EBC12AJ001

24

A roller screen 00EBD11AT001

25

B roller screen 00EBD12AT001

26

A rain scraper 00EAF11AB001

27

Electric two-side plough tripper 00EAC11AF601

28


29


30


31


32


33


34


Operation

Problems



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35


36


37


38


39

Electric two-side plough tripper00EAC12AF604

40


41


42


43


44


45

Electric single-side plough tripper 00EAC11AF201

46

Reciprocating coal feeder 00EAB11AF001

47

Reciprocating coal feeder 00EAB11AF002

48

mechanical sampler for coal as received 00EAU11AE101

49

mechanical sampler for coal as fired 00EBU11AE501

50

mechanical sampler for coal as fired 00EBU12AE501

51

Electronic belt weighing unit

52

TT-1Impulsive bag dust separator02EBP30AZ001

53

TT-2Impulsive bag dust separator03EBP30AZ001

54

1#TT spray dust suppression unit 02EBP30AZ002

55

2#TT spray dust suppression unit 03EBP30AZ002


Date: Date:

00EAT11AF101

Date:


Dongfang Electric:

Date:

Date:



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Appendix 4 Coal Handling Baffle Commissioning Record Baffle Commissioning Record Remote KKS code

Local position indication

Name

00EAC11AA001

electric baffle three-way pipe

00EAC11AA101


00EAC11AA501


00EAC12AA501


00EBD11AT001

A roller screen handspike

00EBD12AT001

B roller screen handspike


Date: Date:

Date:

Directio n correct


Dongfang Electric:

Date:

Feedbac k correct

Operating time Opening time

Date:

Closing time

Date

Result

Signatu re

Remark s



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Appendix 5 Check List for Programmed Control Startup and Shutdown and Interlock for Equipment Flow of CHP No.

Inspection contents

Result

Signature

1．Dock→#1 coal yard Flow 1： ship unloading machine (1# or 2#) →electric three-way pass A side→C-1A belt conveyor (Belt electromagnetic separator) →electric three-way pass A side→C-2A belt conveyor→C-3 belt conveyor→1# stacker reclaimer→#1 coal yard 01

Program control startup (the downstream equipment startup first and continue to the last equipment)

02

Program controlled shutdown (the upstream equipment will shutdown first and continue to shutdown to the last step equipment)

03

Trip in any downstream equipment, trip in all upstream equipments

04

Instant shutdown button on DCS actuates (All equipments shutdown immediately except crusher and screen delay for 5s )

05

Two hard buttons pressed at same time, instant shutdown button actuate(All equipments shutdown immediately except crusher and screen delay for 5s )

2．Dock→coal bunker Flow2： ship unloading machine (1# or 2#) →electric three-way pass A side→C-1A belt conveyor (Belt electromagnetic separator) →electric three-way pass A side→C-2 Abelt conveyor→C-3 belt conveyor→C-4Abelt conveyor (Disc electromagnetic separator) →A roller screen →A ring hammer coal crusher→C-5Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker 01

Program control startup (the downstream equipment starts up first and continue to the last equipment)

02

Program control shutdown (the upstream equipment will shutdown first and continue to shutdown to the last step equipment)

03




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04


05


Flow3： ship unloading machine (1# or 2#) →electric three-way pass A side→C-1A belt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-2A belt conveyor→C-3 belt conveyor→C-4A belt conveyor(Disc electromagnetic separator) →A roller screen →A ring hammer coal crusher→C-5Abelt conveyor(Belt electromagnetic separator) →electric three-way pass Bside→C-6A belt conveyor(Electric two-side plough tripper) →coal bunker 01


02


03


04


05


Flow4： ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-2Abelt conveyor→C-3belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →bypass A→C-5Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker 01


02


03


04



05


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Two hard buttons pressed at same time, instant shutdown button actuate(All equipments shutdown immediately except crusher and screen delay for 5s)

Flow5： ship unloading machine (#1 or #2 )→electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-2A belt conveyor→C-3belt conveyor→C-4A belt conveyor(Disc electromagnetic separator) →bypass A→C-5A belt conveyor(Belt electromagnetic separator) →electric three-way pass B side→C-6B belt conveyor(Electric two-side plough tripper) →coal bunker 01


02


03


04


05


Flow6： ship unloading machine (#1 or #2 )→electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-2Abelt conveyor→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal crusher→C-5Bbelt conveyor(Belt electromagnetic separator) →electric three-way pass B side→C-6Bbelt conveyor(Electric two-side plough tripper) →coal bunker 01


02


03


04


05


Flow7： ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-2Abelt conveyor→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →bypass B→C-5Bbelt conveyor(Belt electromagnetic



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separator) →electric three-way pass B side→C-6Bbelt conveyor(Electric two-side plough tripper) →coal bunker 01


02


03


04


05


Flow8： ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-2Abelt conveyor→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal crusher→C-5Bbelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker 01


02


03


04


05


Flow9： ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-2Abelt conveyor→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →bypass B→C-5Bbelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor (Electric two-side plough tripper) →coal bunker 01




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02


03


04


05


3．Dock emergency→#1 coal yard Flow1： ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-2A belt conveyor→#1 coal yard 01


02


03


04


05


4．#1 coal yard→coal bunker Flow10：#1 coal yard→#1 stacker reclaimer→C-3belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →A roller screen →A ring hammer coal crusher→C-5Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker 01


02




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03


04


05


Flow11：#1 coal yard→#1 stacker reclaimer→C-3belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →A roller screen →A ring hammer coal crusher→C-5Abelt conveyor(Belt electromagnetic separator) →electric three-way pass Bside→C-6Bbelt conveyor(Electric two-side plough tripper) →coal bunker 01


02


03


04


05


Flow12：#1 coal yard→#1 stacker reclaimer→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal crusher→C-5Bbelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker 01


02

Program control shutdown (The upstream equipment shutdown first and continue to the last equipment )

03


04



05


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Flow13：#1 coal yard→#1 stacker reclaimer→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal crusher→C-5Bbelt conveyor(Belt electromagnetic separator) →electric three-way pass B side→C-6Bbelt conveyor(Electric two-side plough tripper) →coal bunker 01


02


03


04


05


5．emergency ground hopper →coal bunker Flow14：#1 coal yard→emergency hopper→C-07belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →A roller screen →A ring hammer coal crusher→C-5Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker 01


02


03


04


05

Two hard buttons pressed at same time, instant shutdown button actuate (All equipments shutdown immediately except crusher and screen delay for 5s )

Flow 15：#1 coal yard→emergency hopper→C-07belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal crusher→C-5Bbelt conveyor(Belt electromagnetic separator) →electric three-way pass B side→C-6Bbelt conveyor (Electric two-side plough tripper) →coal



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bunker 01


02


03


04


05



Date: Date:

Date:


Dongfang Electric:

Date:

Date:



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-M-01-HL-003 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI


Check

DETAIL DESIGN STAGE

Procedure of Primary Air Fan System

Design Scale


N/A

DWG No.


REV

A



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PURPOSE ........................................................................................................................................... 3

2.

SCOPE ................................................................................................................................................ 3

3.

PREPARATION BASIS .................................................................................................................... 3

4.

BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .......................................................... 3

5.

TOOLS AND INSTRUMENT FOR COMMISSIONING.............................................................. 4

6.

PREREQUISITE FOR COMMISSIONING................................................................................... 4

7.

MEASURES FOR COMMISSIONING ORGANIZATION .......................................................... 5

8.

COMMISSIONING PROCEDURE ................................................................................................. 6

9.

SAFETY MEASURES..................................................................................................................... 17

10.

9.1

Safety Rules for Commissioning...................................................................... 17

9.2

Personal Risk and Preventative Measures........................................................ 17

9.3

Equipment Risk and Preventative Measures .................................................... 17 APPENDIX ............................................................................................................................... 17

Appendix 1 Commissioning Condition Checklist.......................................................... 18 Appendix 2 Trial operation parameters of PAF and its system ...................................... 20 Appendix 3 Commissioning Record of Control Dampers in PAF and Its System......... 22 Appendix 4 PAF Dampers Commissioning Record ....................................................... 23



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1.

Purpose

1.1


1.2

Check the reliability of electric and I&C interlock protection and signal device.

1.3


2.

Scope This procedure is applicable for the commissioning of subsystem for vacuum system, including such items as the confirmation of air damper, interlocking and protection test, system commissioning and dynamic adjustment.

3.

Preparation Basis

3.1

Installation and operation manual of PAF (primary air fan)

3.2

Installation and operation manual of sealing fan

3.2

Boiler flue-gas and air system diagram

3.3

Control logic diagram of fan

4.


4.1

There are two operating PAFs with guide blade adjusting.

4.2

Technical parameters of PAF Model of fan: SFG20.5F-C5A Name and parameters

Unit

TB

BMCR

TMCR

Flow at inlet of fan

m3/s

84.29

60.21

57.39

50

50

50

Kg/ m

1.08

1.08

1.08

Total pressure of fan

PA

18713

13361

12078

Shaft power of fan

KW

1973.4

944

822

%

85

87

86

r/min

1490

1490

1490

Inlet temperature Medium density

Total pressure efficiency of fan Rotary speed 4.3

4.4

Adjustable and centrifugal guide blade

℃ 3

Technical parameters of motor Model of motor

YKK630-4

Rated voltage

Rated power

2000 KW

Rated speed

Technical parameters of sealing fan

6300V 1490 r/min



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Name

Sealing fan

Item

Unit

Type

High- pressure centrifugal type

Model

926N0 0112D-7

Q'ty

Set

2

Full pressure

PA

6582

3

42221

Air volume

m /h

Model of motor Motor of sealing fan

Values

Y315m－4

Power

kW

132

Voltage

V

380

Current

A

225

r/min

1460

Rotation speed

5.


5.1

Walkie talkie

5.2

Handheld vibration meter

5.3

Clip-on ammeter

5.4

Tachometer

6.


6.1


6.1.1

Within the scope of system, the site should be level, the road should be fluent, the trench cover is complete and the environment is clean and free of sundries.

6.1.2

Within the scope of system, the plat form, ladder, handrail and guard board are complete, the scaffolds used for construction have been demolished completely.

6.1.3

The sufficient formal illumination is provided on site, if necessary, the temporary illumination should be installed additionally.

6.1.4

The reliable communication equipments are provided on site.

6.1.5

The site shall have sufficient quantity of fire fighting equipment and materials.

6.2


6.2.1

The installation and heat insulation work of all the equipments, pipelines and auxiliary systems have been completed;

6.2.2

The single commissioning for the PAF and sealing fan is qualified;

6.2.3

The installation and debugging for thin oil station are completed;

6.2.4

The installation and debugging for the industrial cooling water system are completed;



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6.2.5

The sundries inside PAF and system are cleared cleanly;

6.2.6

The equipment and each valve have been tagged and named, conforming to the system.

6.2.7

Each manhole door inside the system is closed.

6.3


6.3.1

After the measuring points and measuring elements inside the system are qualified subject to calibration, they are provided with the application conditions.

6.3.2

After the commissioning for thin oil station is competed, the favorable operation condition, normal parameters and the correct display of CRT state have been confirmed.

6.3.3

When single commissioning for the valve is completed, the on/off actions are normal and the on-site location of the limit switch and display of the CRT state are correct.

6.3.4

The interlocking protection alarm test for the system is completed.

6.3.5

The electrical test of motor is qualified, after 2 hour no-load running, the condition is favorable and the turning direction is correct.

6.4

Other necessary conditions

6.4.1

The joint inspection is performed through organizing such related parties as construction, Dongfang Electric, employer and production as well as commissioning; the problems found should be coped completely.

6.4.2

The preparation work for production and commissioning is completed; the operators should be arranged completely and qualified via the training and examination. The operation regulation and system diagram are reviewed and approved; the operating tools and the operation log are prepared properly.

6.4.3

The necessary maintenance tools and materials are prepared;

6.4.4

The command and organizing system for commissioning is perfect, with explicit division of labor.

6.4.5

The commissioning data, tools, instruments, gauge and the record list are prepared completely;

6.4.6

The personnel on instrument control, electrical and maintenance from the installation organization arrive at the site.

6.4.7

The disclosure work on measures is completed.

7.


7.1



◆


◆

Preparation of instruments and equipment required for commissioning；

◆



7.2

7.3

7.5

7.6

8.

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◆


◆


◆




◆

Be responsible for inspection, maintenance and defect elimination of equipment under commissioning；

◆

Prepare maintenance tools and materials necessary for commissioning；

◆

Assist the commissioning contractor in the commissioning of subsystems；

◆

Be responsible for temporary coordination of local I&C components and connection terminals.


7.4





◆


◆


◆

Be responsible for patrol inspection, check, and normal maintenance of system and equipment;

◆

Be responsible for dealing with the accidents occurred in commissioning。


Be responsible for supervision and control over commissioning work;

◆

Coordinate with commissioning contractor, the Owner, and other contractors in the commissioning.

◆


◆

Organize analysis and settlement of major technical issues in commissioning。



◆


◆

Accept the results of commissioning。




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8.1

Cold check and transmission test of damper baffle

8.1.1

Check and accept motorized and pneumatic on/off damper baffle and record the following data: Check if KKS code, designation and local position indication is correct, if the remote operation direction and feedback is satisfactory, valve open (close) time, test date and signature by person in charge of test. Refer to Appendix 4 for detail.

8.1.2

Check the motorized or pneumatic regulating valves and enter the following data on the records: KKS code, designation, local position indications and feedback indications corresponding to upward command of 0%, 50%, 75%, and 100% and downward command of 100%, 75%, 50% and 0% respectively, confirm if local position indication is correct, test date, signature by person in charge of test. Refer to Appendix 3 for other requirements.

8.2

Check Interlock Protection and Alarm Check（note: the test project on interlock protection is based on the logical discuss result.）

8.2.1

The power supply of the PAF shall be placed in the test location to inspect the items below: (1) Start-up the PAF through computer and feedback on computer is correct; (2) Stop the PAF through computer and feedback on computer is correct; (3) Reliable emergency buttons

8.2.2

The interlock protection test of the PAF covers:

8.2.2.

1 Inspection for the allowable condition for PAF A(B) starting

No.

Test item

Starting condition of PAF A (1)

PAF A is free of tripping condition;

(2)

PAF A stops

(3)

The control damper at inlet of PAF A is closed properly

(4)

The damper at outlet of PAF A has been closed

(5)

Without MFT signal

(6)

Any forced draft fan is operating

(7)

Any induced draft air is operating

(8)

Without the alarm signal on high temperature for PAF A

(9)

The oil pressure is normal in the oil station for PAF A

(10)

The oil station of PAF A allows the main unit starting

(11)

The oil station of PAF A is free of signal alarm

(12)

The primary air damper at outlet of air preheater A has opened, or primary air damper at outlet of air preheater B has opened and the interconnection valve at outlet of PAF has opened

Starting condition of PAF B

Fixed value

Results

Remarks



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(1)

PAF B is free of tripping condition;

(2)

PAF B stops

(3)

The control damper at inlet of PAF B is closed properly

(4)

The damper at outlet of PAF B has been closed

(5)

Without MFT signal

(6)

Any forced draft fan is operating

(7)

Any induced draft air is operating

(8)

Without the alarm signal on high temperature for PAF B

(9)

The oil pressure is normal in the oil station for PAF B

(10)

The oil station of PAF B is free of signal alarm

(11)

The primary air damper at outlet of air preheater B has opened, or primary air damper at outlet of air preheater A has opened and the interconnection valve at outlet of PAF has opened

8.2.2.2

Inspection on tripping condition for the protection interlinking of PAF

No.

Test item

Tripping condition of PAF A (1)

After PAF A operates for 60s, the outlet damper of PAF A is closed;

(2)

Air preheater A stops

(3)

Two forced draft fans and two air induced draft fans stop uniformly

(4)

The vibration of bearing in X-direction at the driving end of PAF A is high

(5)

The vibration of bearing in Y-direction at the driving end of PAF A is high

(6)

The vibration of bearing in X-direction at the non-driving end of PAF A is high

(7)

The vibration of bearing in Y-direction at the non-driving end of PAF A is high

(8)

MFT

(9)

Emergency button action

(10)

Heavy failure in oil station of PFA A

(11)

Oil pump in oil station of PFA A stops completely

(12)

The bearing temperature at driving end of PFA A is high high

(13)

The bearing temperature at non-driving end of PFA A is

Fixed value

Results

Remarks



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high high (14)

The bearing temperature at motor driving end of PFA A is high high.

(15)

The bearing temperature at motor non-driving end of PFA A is high high.

(16)

The motor stator U- phase temperature of PFA A is high high.

(17)

The motor stator V- phase temperature of PFA A is high high.

(18)

The motor stator W- phase temperature of PFA A is high high.

Tripping condition of PAF B (1)

After PAF B operates for 60s, the outlet damper of PAF B is closed;

(2)

Air preheater B stops

(3)

Two forced draft fans and air induced draft fan stop uniformly

(4)

The vibration of bearing in X-direction at the driving end of PAF B is high

(5)

The vibration of bearing in Y-direction at the driving end of PAF B is high

(6)

The vibration of bearing in X-direction at the non-driving end of PAF B is high

(7)

The vibration of bearing in Y-direction at the non-driving end of PAF B is high

(8)

MFT

(9)


(10)

Heavy failure in oil station of PFA A

(11)

Oil pump in oil station of PFA B stops completely

(12)

The bearing temperature at driving end of PFA B is high high.

(13)

The bearing temperature at non-driving end of PFA B is high high.

(14)

The bearing temperature at motor driving end of PFA B is high high.

(15)

The bearing temperature at motor non-driving end of PFA B is high high.

(16)

The motor stator U- phase temperature of PFA B is high high.

(17)

The motor stator V- phase temperature of PFA B is high high.


(18)

8.2.2.3


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The motor stator W- phase temperature of PFA B is high high.

Procedure on startup of PAF A/B

No.

Test item

Fixed value

Results

Remarks

Fixed value

Results

Remarks

Procedure on startup of PAF A (1)

Step 1: Start the oil station of fan

(2)

Step 2:open the primary air damper at outlet of air preheater A

(3)

Step 3: close the primary air damper at outlet of PAF A Place the guide blade of PAF A on the minimum location

(4)

Step 4: start the motor of PAF A

(5)

Step 5: open the primary air damper at outlet of PAF A in delay.

Procedure on startup of PAF B (1)

Step 1: Start the oil station of fan

(2) Step 2: Open the primary air damper at outlet of air preheater B (3)

Step 3: close the primary air damper at outlet of PAF B; Place the guide blade of PAF B on the minimum location

(4)

Step 4:

(5)

Step 5: open the primary air damper at outlet of PAF B in delay.

8.2.2.3

start the motor of PAF B

Procedure on shutdown of PAF A/B

No.

Test item

Procedure on shutdown of PAF A (1)

Step 1: place the guide blade of PAF B on the minimum location

(2)

Step 2:

(3)

Step 3: close the primary air damper at outlet of PAF B

stop the motor of PAF


(4)

Step 4:


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stop the oil station of PAF in delay

Procedure on shutdown of PAF B (1)

Step 1: place the guide blade of PAF B on the minimum location

(2)

Step 2:

(3)

Step 3: close the primary air damper at outlet of PAF B

(4)

Step 4:

8.2..2.5

stop the motor of PAF stop the oil station of PAF in delay

Interlock test for the outlet damper of PAF

No.

Test item

(1)

After the PAF is started, interlock and open up the outlet damper in delay; if the PAF on another side stops, the outlet damper and the inlet guide blade should be closed by means of interlock.

(2)

After the PAF is started, but the PAF on another is operating, interlock and close the outlet damper of PAF and the inlet guide blade.

(3)

After the PAF stops completely, interlock and open up the outlet damper.

8.2.2.6 No.

Fixed value

Results

Remarks

Fixed value

Results

Remarks

Results

Remarks

Interlock test for the cold air damper at outlet of PAF Test item

Cold air damper at outlet of PAF A (1)

Conditions on closing by means of interlock PAF A stops, PAF B operates and the outlet damper of PAF B fails to close.

Cold air damper at outlet of PAF B (1)

8.2.2.7 No.

Conditions on closing by means of interlock PAF B stops, PAF A operates and the outlet damper of PAF A fails to close.

Interlock test for the interconnection valve at outlet of PAF Test item

Interconnection valve at outlet of PAF (1)

Conditions on opening by means of interlock Two PAFs stop completely and delay for 80s or two air

Fixed value



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preheaters are operating and any PAF is operating. (2)

8.2.2.8

Interlock closing conditions：(or) (3) Air preheater A stops and PFA B is operating (4) Air preheater B stops and PFA A is operating (5) The PAF A stops and delays for 65s, PAF B is operating, the damper actuator at outlet of PAF A is not closed and the moving blade of PAF A is not closed properly. (6) The PAF B stops and delays for 65s, PAF A is operating, the damper actuator at outlet of PAFB is not closed and the moving blade of PAF B is not closed properly.

Interlock test in the oil station of PAF

No.

Test item

Oil station of PAF A (1)

Allowable start condition in the oil station: the oil level of oil tank in the oil station isn’t low;

(2)

Allowable shutdown condition in the oil station: PAF A stops and delays for 5 minutes.

(3)

When interlock is put into operation, PAF A is operating and 1# oil pump is operating, the oil pressure in the oil station of PAF A is low, start 2# oil pump by means of interlock.

(4)

When interlock is put into operation, PAF A is operating and 2# oil pump trips due to operating failure, 2# oil pump t in the oil station of PAF A is out of operation, start 2# oil pump by means of interlock.

(5)

When interlock is put into operation, PAF A is operating and 2# oil pump is operating, the oil pressure in the oil station of PAF A is low, start 1# oil pump by means of interlock.

(6)

When interlock is put into operation, PAF A is operating and 2# oil pump trips due to operating failure, 1# oil pump in the oil station of PAF A is out of operation, start 1# oil pump by means of interlock.

Heater in the oil station of PAF A (1)

Allowable start condition for the heater in the oil station: any oil pump in the oil station of PAF A is operating and the oil level of oil tank in the oil station for PAF A isn’t low;

(2)

Interlocking and starting condition for the heater: when interlock is put into operation, any oil pump in the oil station of PAF A is operating and the oil level of oil

Fixed value

Results

Remarks



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tank in the oil station for PAF A is low; (3)

Interlocking and shutdown condition for the heater: when interlock is put into operation, the oil level of oil tank in the oil station for PAF A is high or the oil level of oil tank is low;

Oil station of PAF B (1)

Allowable start condition in the oil station: the oil level of oil tank in the oil station isn’t low;

(2)

Allowable shutdown condition in the oil station: PAF B stops and delays for 5 minutes.

(3)

When interlock is put into operation, PAF B is operating and 1# oil pump is operating, the oil pressure in the oil station of PAFB is low, start 2# oil pump by means of interlock.

(4)

When interlock is put into operation, PAF B is operating and 1# oil pump trips due to operating failure, 2# oil pump t in the oil station of PAF B is out of operation, start 2# oil pump by means of interlock.

(5)

When interlock is put into operation, PAF B is operating and 2# oil pump is operating, the oil pressure in the oil station of PAF B is low, start 1# oil pump by means of interlock.

(6)

When interlock is put into operation, PAF B is operating and 2# oil pump trips due to operating failure, 1# oil pump t in the oil station of PAF B is out of operation, start 1# oil pump by means of interlock.

Heater in the oil station of PAF B (1)

Allowable start condition for the heater in the oil station: any oil pump in the oil station of PAF B is operating and the oil level of oil tank in the oil station for PAF isn’t low;

(2)

Interlocking and starting condition for the heater: when interlock is put into operation, any oil pump in the oil station of PAF B is operating and the oil level of oil tank in the oil station for PAF B is low;

(3)

Interlocking and shutdown condition for the heater: when interlock is put into operation, the oil level of oil tank in the oil station for PAF B is high or the oil level of oil tank is low;

8.2.2.9

Inspection on alarm condition of PAF

No.

Test item

(1)

When the bearing temperature of PAF is high, give an alarm.

Fixed value

Results

Remarks



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(2)

When the bearing temperature of PAF motor is high, give an alarm.

(3)

When the coil temperature of PAF motor is high, give an alarm.

(4)

When the bearing vibrates heavily, give an alarm.

(5)

When the oil level of the oil tank in the oil station is low, give an alarm.

(6)

When the oil temperature in the oil station of PAF is low, give an alarm.

(7)

When the oil pressure of lubrication oil is low, give an alarm.

8.2.2.10

Inspection on interlock protection for sealing fan

No.

Test item

Sealing fan A (1)

Startup permissive condition of sealing fan A(and)

1)

The electrical is free of failure

2)

Any fan is operating

3)

The inlet damper is les than 5%.

(2)

Shutdown permissive condition of sealing fan A (or)

1)

The coal mills stop completely

2)

Another sealing fan is operating and the pressure is normal;

(3)

Tripping condition of sealing fan A(or)

1)

Electrical failure

2)


3)

The PAFs stop completely and delay for 15s.

Sealing fan B (4)

Startup permissive condition of sealing fan B (and)

1)

The electrical is free of failure

2)

Any fan is operating

3)

The inlet damper is les than 5%.

(5)

Shutdown permissive condition of sealing fan B (or)

1)

The coal mills stop completely

2)

Another sealing fan is operating and the pressure is normal;

(6)

Tripping condition of sealing fan B(or)

Fixed value

Results

Remarks


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Page 15 of 23

1)

Electrical failure

2)


3)

The PAFs stop completely and delay for 15s.

(7)

Interlocking and starting condition of sealing fan

1)

The backup is put into operation; a sealing fan is operating and the pressure on the main pipeline of the air sealing system ≤9kpa, delaying for 1s and starting the backup sealing fan by means of interlock.

2)

The backup is put into operation and a operating sealing fan trips and start the backup sealing fan by means of interlock.

(8)

8.3


Interlocking condition for the outlet valve of sealing fan

1)

The fan on this side operates and delays for 2s, opening up by means of interlock.

2)

The fan on this side operates is out of operation, close by means of interlock.

Necessary condition for PAF and prior to system starting (1)

Within the plant, the trench cover is complete, the ladder and the handrail are perfect and the sundries are cleaned clearly.

(2)

The completion for installation of the PAF and system are confirmed, with complete system.

(3)

The air passage of PAF system and the silencer at the inlet are cleared cleanly, free of the foreign matters to destroy the fan.

(4)

The closure for the manhole and inspection hole for the air preheater body and at outlet of air passage is completed;

(5)

The adjustment for the damper and baffle has completed and the acceptance is qualified.

(6)

The installation, verification and acceptance for the measuring meter are qualified;

(7)

Related transmission test on interlocking protection is qualified, and the constant value setting for related protection and alarm is completed.

(8)

The electrical test for motor has been completed;

(9)

The test for the oil station of PAF is completed, conforming to the requirement.

(10) The commissioning for air preheater and system is completed; the commissioning result conforms to the requirement. (11) The commissioning for induced draft fan and system is completed; the commissioning result conforms to the requirement. (12) The action for the emergency button of fan is reliable. (13) The PAF and rotator can be turned normally by hands; (14) The commissioning for the fan and motor monomer is completed, the motor and the



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coupler of fan restore properly. (15) Each bearing for the fan and motor has sufficient lubricating agent; (16) The industrial illumination and the accident illumination of equipment are perfect, the sufficient illumination can be ensured; (17) The communication system is reliable and the contact is fluent. (18) The such utility system as the compressed air is provided with the commissioning condition. 8.4

The commissioning and shutdown for the PAF and system

8.4.1

Check to be completed prior to system startup (1)

Each interlocking test for the fan and the system is qualified;

(2)

The on/off for the outlet damper and guide balde is confirmed to be flexible, in addition, the site openness is consistent with display of CRT.

(3)

The insulation for such equipments as the fan is qualified, the power supply is provided;

(4)

Various meters for PAF system are put into operation.

(5)

The commissioning for the oil pump in the oil station of fan is normal.

错误！链接无效。 8.4.2

8.4.3

8.5

The cooling water system is normal;

PAF starting (1)

Close the outlet damper at outlet of fan;

(2)

Start the oil station and require that the oil pump motor is provided with feedback signal;

(3)

Shut off the guide blade of fan;

(4)

Start the PAF and open up the air damper

(5)

Adjust the blade up to the angle required;

(6)

Confirm that the sealing fan is provided with the starting condition and start the sealing fan.

Shutdown of PAF (1)

Shut off the guide blade of fan;

(2)

Stop the fan;

(3)

Shut off the outlet damper of fan;

(4)

Stop the oil pump in the oil station in delay;

Operation of system during integral start-up According to the no-load stage, load stage and the full load stage as well as 30-day reliable operating stage, the reliability for the system operating should be tested.

8.5.1

Dynamic regulation of system (1)

Primary airflow adjusting;

(2)

Primary air pressure adjusting;

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure 8.5.2


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Complete trial operation record Refers to Appendix 2 for the main parameters during stating the commissioning.

9.

Safety Measures

9.1


9.1.1

The parties participating in the commissioning shall be ware of and observe relevant safety regulations on the site, wear proper clothes and personal safety protection articles.

9.1.2

In case that any accident damages the equipment or hurts person happened or possibly happen during commissioning, stop commissioning immediately and put the equipment to the lowest energy state. Then investigate the cause and take corrective measures.

9.1.3


9.1.4


9.2


9.2.1


9.3


9.3.1

When the PAF and the system start up the commissioning for the first time, the relevant personnel must be designated to strictly monitor the equipment site, and the reliable communication means shall be employed to contact with the central control room.

9.3.2

When the PAF is commissioning, the start time and current should be strictly monitored; if the start time is too long or the current swings abnormally, stop the operation timely;

9.3.3

When starting the PAF, the rotating direction should be noticed, if the turning direction is opposite, stop the operation timely;

9.3.4

Take notice of monitoring the variation of such parameters as oil pressure, axis temperature vibration and bearing temperature as well as the current, avoiding producing the severe accidents.

10.

Appendix



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Items

Requirements

Result

Environmental Conditions (1)



□Yes □No

(2)


Complete Removed

□Yes □No

(3)

Illuminating

Sufficient

□Yes □No

(4)


Reliable

□Yes □No

Fire apparatus


□Yes □No

(5) 2.

Maintenance conditions (1)

Installation and heat insulation work

All fulfilled

□Yes □No

(2)

Commissioning of fan monomer

Qualified

□Yes □No

(3)

Thin oil station

The debugging is qualified

□Yes □No


Commissioning is completed and commissioning can be performed.

□Yes □No

(5)

Inner sundries

Completing the clearing

□Yes □No

(6)

Equipment and valve

Tagging, correct naming

□Yes □No

(7)

Manhole door

Closed fully

□Yes □No

Measuring points and the measuring gauge

The calibration is qualified and the indication is correct

□Yes □No

Thin oil station

The operation is favorable and the display of status is correct.

□Yes □No

Single valve

After completing the commissioning, the action is normal, the display of status is correct.

□Yes □No

Interlock protection and alarm

Test eligible

□Yes □No

(4)

3. (1)

Electrical and I&C condition

(2)

(3)

(4)

Verified by

Remar ks



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(5)

The test is qualified, subject to 2-h no-loading operation, the condition is favorable and the rotary direction is correct.

□Yes □No

Inspection work of system

Completed, the treatment of defects is completed;

□Yes □No

Production preparing

The operators are provided completely, the operation tools are prepared properly and the operation log is prepared properly.

□Yes □No

(3)


Complete

□Yes □No

(4)

Command and organization system

Perfect, the division of work is explicit.

□Yes □No

(5)

Commissioning data, tools, instruments, meters and record form,

Preparation is complete

□Yes □No

6)



□Yes □No

(7)

Disclosure of measures

Fulfilled

□Yes □No

Date:



4.

Other conditions

(1) (2)


Date: Date:

Dongfang Electric:

Date:

Date:



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Appendix 2 Trial operation parameters of PAF and its system Trial operation parameters of PAF and its system No. 1 2 3 4 5

Item

Moving blade opening, PAF A Motor current, PAF A

Outlet air pressure, PAF A Differential pressure (DP), PAF A

Bearing vibration, PAF A

Unit % A KPa KPa mm/s

6

Outlet primary air temperature, APH A

℃

7

Inlet primary air temperature, APH A

℃

8

Bearing temperature, PAF A

℃

9

Outlet primary air pressure, APH A

KPa

10

Outlet/inlet primary air differential pressure, APH A

KPa

11

Inlet air temperature, PAF A

℃

12

Outlet air temperature, PAF A

℃

13

Motor bearing temperature, PAF A

℃

14

Motor winding temperature, PAF A

℃

15

Moving blade opening, PAF B

%

16

B primary fan current Motor current, PAF B

A

Data

Remarks



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17

Outlet air pressure, PAF B

KPa

18

Differential pressure (DP), PAF B

KPa

19

Bearing vibration, PAF B

mm/s

20

Outlet primary air temperature, APH B

℃

21

Inlet primary air temperature, APH B

℃

22

Bearing temperature, PAF B

℃

23

Outlet primary air pressure, APH B

KPa

24

Outlet/inlet primary air differential pressure, APH B

KPa

25

Inlet air temperature, PAF B

℃

26

Outlet air temperature, PAF B

℃

27

Motor bearing temperature, PAF B

℃

28

Motor winding temperature, PAF B

℃


Date: Date:

Date:


Dongfang Electric:

Date:

Date:



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Appendix 3 Commissioning Record of Control Dampers in PAF and Its System Commissioning Record of Control Dampers in PAF and Its System Feedback of ascending and descending instruction values KKS code

Name of damper

Date 0%

X0HFE10AA101XB

Moving blade, PAF A

X0HFE20AA101XB

Moving blade, PAF B

X0HFW11AA101XB

Moving blade, SAF A

X0HFW21AA101XB

Moving blade, SAF B

25%

50%

75%

100%

75%


Date:


Date:

Contractor:

Date:

Dongfang Electric:

Date:

Owner

Date:

50%

25%

0%

Result

Signa ture

Remar ks



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Appendix 4 PAF Dampers Commissioning Record PAF Dampers Commissioning Record

KKS code

Name of damper

X0HFE10AA001XB

OUTLET MOTORIZED DAMPER, PAF A

X0HFE20AA001XB

OUTLET MOTORIZED DAMPER, PAF B

X0HFE30AA001XB

PAF OUTLET INTERCONNECTING MOTORIZED DAMPER

X0HFE11AA001XB

PAF A OUTLET COOLING AIR MOTORIZED DAMPER

X0HFE21AA001XB

PAF B OUTLET COOLING AIR MOTORIZED DAMPER

X0HFW13AA101XB

SAF EXHAUST ASH VAVLE


Remote Directi on


Date:


Construction Contractor:

Date:

Dongfang Electric:

Owner

Date:

Feed back

Operating time On (Open)

Date: Date:

Off (Close)

Date

Result

Signatu re

Remark s



Owner’s DWG No.

PT.PLN(PERSERRO)

0702-00-M-01-QHD-001

PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI


CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY SiChuan Electric Power Commissioning & Test Institute Approval

Check

Date

DETAIL DESIGN STAGE

Procedure of Ash Removal and Deslagging System

Review Design Scale


N/A

DWG No.

SCCTI-TS-GL-CS -015-2009A

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A



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Table of Contents

1.

PURPOSE ........................................................................................................................................... 3

2.

SCOPE ................................................................................................................................................ 3

3.


4.


5.


6.


7.


8.


9.

SAFETY MEASURES..................................................................................................................... 23

9.1


9.2


9.3


10.

10.1

Appendix 1 Commissioning Condition Checklist............................................ 25

10.2

Appendix2 Valves Commissioning Record...................................................... 26



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1.

Purpose

1.1


1.2

Check the electrical and I&C protection interlock and signal devices of the ash and cinder and dust handling system and confirm they are functioning correctly and reliably.

1.3


2.

Scope This procedure applies to commissioning of ash removal and deslagging subsystem of boiler, including startup commissioning of ash removal and deslagging system and electrostatic precipitator (ESP).

3.

Preparation Basis

3.1

Instructions of equipment relating to deslagging system;

3.2

Instructions of equipment relating to ash removal system;

3.3

Flow diagram and control logic diagram of boiler deslagging system；

3.4

Flow diagram and control logic diagram of boiler ash removal system.

4.


4.1

Brief description of deslagging system and equipment

4.1.1

Dry-type mechanical deslagging system The deslagging system is designed according to the following technological process: Dry-type slag remover- Slag crusher -Bucker elevator-Slag storage- Slag truck. Slag from the furnace continuously enters the upper chute where it has been cooled by air and broken, and then caught by dry-type slag remover and conveyed to the slag storage by the bucker elevator. In addition, flying ash from the economizer has also been conveyed to the slag storage. One slag storage with volume of 100m3 shall be equipped for each boiler. The large sized slag is conveyed to the double shaft mixer by feeder where it is mixed with water to form the wetted slag with water content of 25％ which has then been conveyed to the slag truck. Large sized slag shall be transported by self-unloading trucks to the ash yard or other users for integrated reuse. The ash storage shall be equipped with an auxiliary system consisting of a bag ash collector and three (3) air cannons to reduce the dust and to ease the slag discharge.

4.1.2

Main equipment and their technical parameters No.

Equipment

Q’ty/ Specification / Parameters

1

Dry-type slag remover

One set for each boiler, model: GBL12A×25, with slag pit, large sized slag squeezer, etc.

capacity: 4-5 t/h

2

Single roller slag crusher

One set for each boiler, capacity: 5.50t/h，5.5KW; power of motor: 6 kW, 380v.

3

Bucker elevator

One set for each boiler, model: ZBT600×22，capacity: 5.50t/h，10 KW; power of motor: 12kw,380v .


4.2


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4

Slag storage

One set for each boiler, diameter: Ф7.6m，capacity:100m3

5

Bag ash collector

One set for each boiler, power: 7.5KW, volume: 50m3.

6

Pressure vacuum relief valve

One set for each boiler, model: 580.

7

Double shaft mixer

One set for each boiler with slide gate and feeder, capacity: 100t/h, 22kw

8

Air reservoir

One set for each boiler, C-2/0.8, 2 m3, 0.8MPa

9

Air cannon

Three (3) sets for each boiler, model: KL-300

General Description of Ash removal system and Equipment The following principles shall be adopted by the ash removal and deslagging system: The flying ash and slag shall be handled separately; dry flying ash shall be handled keeping its dry condition; coarse ash and fine ash shall be handled separately. Flying ash shall be collected in the ash silo where it mixed with water by wet mixer to form the wetted ash with water content of 15% to 25% and then transported to the ash yard by self unloading trucks or loaded by the bulk loader into the tank cars and transported to other integrated users. Two units are designed with one ash removal unit for each boiler, but the control system for ash removal, compressed air system, facilities and equipment at the ash silo area shall be shared by two boilers.

4.2.1

Positive pressure dense phase conveying system This ash removal system adopts the positive pressure and dense phase type dry pneumatic conveying system. The main equipment for each boiler includes four (4) ash conveyers under the economizer ash hopper ( ash tanks), forty (40) conveyers (conveyer hoppers) under the ash hoppers of 1#, 2#, 3# and 4# fields of ESP (8 for each field). The ash hoppers are equipped with two (2) gasification fans each of which is equipped with an electric heater. The system also includes ash conveying pipelines, domed valve, slide gate valve, pneumatic valve, pneumatic change-over valve, conveying air compressor, refrigerated air dryer, air storage system, electrical equipment, PLC control system, etc. The air needed for dry ash conveying is supplied by four (4) air compressors specially used for ash conveying and the air source for the control system is furnished by the instrument service air compressors. Dry ash collected by the economizer and ESP shall conveyed through conveying pipeline by the air compressor to the slag storage and two (2) ash silos separately. Each silo is equipped with a pulse bag ash collector, two (2) level gauges. The fluidizing air for the ash silo is supplied by two (2) gasification fans and each silo is equipped with a bulk loader and a double shaft mixer. The conveyer hoppers for all fields of each ESP have the group operation respectively and the conveying system of each ESP shall be divided into four groups (A,B,C and D). One pipeline is specially used for ash conveying of the field 1, one pipeline is for economizer and one pipeline is commonly used by the fields 2,3 and 4 for ash conveying. Each boiler has a main pipeline for ash conveying. All equipment of the flying ash conveying system shall be able to handle the maximum quantity of flying ash produced under the boiler operating condition of MCR with a sufficient surplus capacity. The system could be operated either continuously or intermittently and its down period has been considered.

4.2.2

The air compressor house and fluidized air system for ESP Two boilers shares one air compressor house in which three (3) screw air compressors (two



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for operation and one for standby, with function of automatic pressure control) three (3) refrigerated air dryers and three (3) air reservoirs are installed. Two (2) ash hopper gasification fans and two (2) ash hopper heaters have been equipped for each ESP. The refrigerated air dryers and air compressors are connected using the piping-main scheme. The air entering the refrigerated air dryers (two in operation and one in standby) shall be controlled by its inlet valve to get quality of the air. 4.2.3

Ash silo, its fluidization, dust collection and ash unloading system Two silos shall be shared by two boilers. The bottom of the silo is of flat type with a fluidizing chute set on it for smooth ash disposal. The fluidizing air shall be supplied by the two (2) silo gasification fans (one is in operation and other is for standby) with one electric air heater installed at the outlet of each of it that can heat the fluidizing air to about 150℃. On the top of the ash silo there are two (2) bag dust collectors used to purify the exhaust. There are two (2) double shaft mixers installed on the bottom of the ash silo in which the ash is mixed with water to form the wetted ash with water content of 25％ which has then been transported to the ash yard for storage or used by the integrated users. There is also one bulk loader used for taking the dry ash for use when necessary. Considering that the dry ash loading job is intermittent one, the equipment at ash silo area will be locally controlled and their operating conditions will be remotely monitored. One bag dust collector shall be equipped on the top of each of the two ash silos. The silo is equipped with high/low and continuous level signal devices and the instrument air of ash silo will come from the instrument service air.

4.2.4

Main equipment and its technical parameters Design Parameters No .

Name

Qty. /Model

Flow

Pressure

1

Screw air compressor

3 sets for 2 boilers. LS25S-300LWC-SULL

21m3/min

0.75MPa

2

Refrigerated air dryer

3 sets for 2 boilers. JRL-50NW，5KW

30m3/min

0.8MPa

Prefilter

3 sets for 2 boilers.

JHF9-30

30m3/min

0.8MPa

JHF9-30

3

0.8MPa

3

Afterfilter

3 sets for 2 boilers.

30m /min 3

Air reservoir

One set for two boilers. Model: C-20/0.8

20m

0.8MPa

4

Air reservoir

3 sets for 2 boilers. Model: C-6/0.8

6m3

0.8MPa

5

Gasification fan

Four for two BKD-3000,30KW

boilers.

11.9m3/min

0.0784MPa

6

Air electric heater

Six sets for two boilers. 45KW， 380V

11.9m3/min

0.0784MPa

7

Ash transmitter of field 1

Eight sets for two boilers.

Capacity: 9.5T/H

8



Capacity: 6.3T/H

9



Capacity: 1.27T/H

10



Capacity: 0.24T/H

11

Double shaft mixer

Two sets for two boilers. Model: SZ200

Capacity: 100T/H, P=22KW



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Page 6 of 30 Capacity: 8.42Nm3/h, 88.2KPa

12

Gasification fan

Two sets for two boilers. Model: GCH-A-60

13

Gasification Box of ash hopper

Sixty four sets for two boilers.

14

Ash silo

Two sets for two boilers.

500 m3

15

Bag dust collector

Two sets for two boilers.

80 m3

16

Pressure vacuum relief valve

Two sets for two boilers. Model: 508

17

Bulk loader

Two sets for two boilers. Capacity: 100T/H

4.2.5

300X300

Slag Composition of Design Coal No.

Name

Symbol

Unit

Designed coal type

Variation range of coal type

1

Silica

SiO2

%

11.7

10--32

2

Ferric oxide

Fe2O3

%

34

8.3--38.5

3

Alundum

Al2O3

%

12

2.63-29.2

4

Calcium oxide

CaO

%

14

4.18--20

5

Magnesium oxide

MgO

%

12

8.30--16

6

Titanic oxide

TiO2

%

0.3

0.10--0.7

7

Sulfur trioxide

SO3

%

13.67

0.12--15

8

Phosphorus pentasulfide

P2O5

%

1.15

0.5--22.7

9

Sodium oxide

Na2O

%

0.19

0.15--2

K2O

%

0.98

0.05--2.4

(1) Distortion temperature

DT

℃

1150

1150

(2) Softening temperature

ST

℃

1200

1200

(3) Melting temperature

FT

℃

1300

1300

10 Potassium oxide 11 Melting point of ash

4.3

General description of rejects handling system Each boiler shall be equipped with five (5) medium speed mills for coal pulverizing system of this phase of project each of which shall have a rejects discharge gate valve and a rejects discharge hopper with volume of 0.5 m3. During the normal operation the mill rejects will be discharged with help of a self-unloading trolley by manual operation.

4.4

Brief introduction to the ESP system Each unit shall be equipped with one ESP of horizontal type with two compartments and four fields and each ESP shall have sixteen (16) large sized ash hoppers. The positive pressure and dense phase pneumatic conveying mode shall be adopted by ESP.



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Working principle: During the period of the dusty flue gas passing through the high-voltage fields, the dust particles colliding with basic and negative ions and electrons between electrodes or in the ion diffusion movement become a kind of particles carrying electrons and ions that moves toward the opposite electrode and have been adsorbed on them under forces of the electrical fields. Such dust particles could be dropped into the ash hoppers by rapping the electrode plates.

5.


5.1

Walkie talkie；

5.2

Portable vibration meter;

5.3

Digital multimeter.

6.


6.1.1

The installation work for the system and all equipment has been completed.

6.1.2

All foreign matters inside the system and equipment have been cleaned up.

6.1.3

Eight (8) hours test operation for each single equipment has been completed and all defects have been eliminated.

6.1.4

Air ventilation test has been completed and all defects have been eliminated.

6.1.5

Forty eight (48) hours aeration-drying for ash silo has been finished.

6.1.6

The pneumatic and hand-operated valves position indication conforms to their real position proved by operating of them.

6.1.7

All ash conveying pipelines have been purged by the air pressure test.。

6.1.8

Commissioning of I&C, level gauges, pressure switches, etc. has been finished and is ready for operation

6.1.9

All safety valves of the system completely equipped and have been calibrated for satisfaction.

6.1.10

Commissioning of PLC system is finished and it has a correct logic relationship.

6.1.11

Commissioning of interlock and audio & visual alarm device has been finished and tested for satisfaction.

6.1.12

The site should have smooth service passage and sufficient lighting

6.1.13

Communication equipment is sufficient for use and its performance is reliable.

6.1.14

Fire-fighting equipment is sufficient and convenient for use.

6.1.15

Overhaul tools and materials with great varieties are sufficient for use.

6.1.16

Tools and instrument for commissioning have well been prepared.

7.

Measures for Commissioning Organization This procedure shall be executed under the organization of commissioning contractor. The construction contractors shall cooperate closely with each other according to their respective



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work responsibilities so as to guarantee safe and effective implementation of commissioning. The division of works is as follows: 7.1

7.2

7.3



◆


◆


◆


◆


◆


◆




◆

Be responsible for inspection, maintenance and defect elimination of equipment under commissioning;

◆


◆


◆



7.4

7.5




◆


◆


◆


◆

¡¡Be responsible for dealing with the accidents occurred in commissioning。



◆


◆


PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure ◆ 7.6


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◆


◆


8.


8.1

Cold check and transmission test of valve

8.1.1

Check the motorized on-off valves and enter the following data on the records: KKS code, designation, confirming if the local position indication is correct, open/close time of valves, test date, signature by person in charge of test. Refer to Appendix 2 for other items.

8.1.2

Check and accept pneumatic switching gate (valves) and record the following data: KKS code, designation, confirming if local position indication is correct, if the operating direction on the computer and the remote feedback are correct, test date, signature by person in charge of test. Refer to Appendix 2 for other items

8.2

Checking of interlocking and alarm system ( Note: The interlocking test items are subject to the result of the discussion on logic.) Set the power at “TEST” position to check the following items: (1) Start the equipment from the computer and have a correct feedback on it. (2) Stop the equipment from the computer and have a correction feedback on it. (3) Emergency pushbutton worked reliably.

8.3

Checking of the interlocking and protection system of the ash removal system.

8.3.1

Ash hopper gasification fan system Operation mode: 1 in operation, 1 in standby No.

Test item

(1)

1# Electric heater startup condition: gasification fan in operation

(2)

1# Gasification fan startup condition: free of fault and remote control is possible

(3)

1# Gasification fan shutdown condition: electric heater shutdown

(4)

1#Gasification fan tripping, interlocked shutdown of electric heater

(5)

2# Electric heater startup Gasification fan is in operation

(6)

2# Gasification fan startup condition: fault free and remote

(7)


(8)

2#

Gasification

fan

tripping,

Fixed value

condition:2#

interlocked

Results

Remarks



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shutdown of electric heater

8.3.2

(9)

Enable interlocking to open outlet valve of 2# gasification fan and gives an alarm and start 2# standby gasification fan when 1# gasification fan tripping or stopped.

(10)

Enable interlocking to open outlet valve of 1# gasification fan and gives an alarm and start 1# standby gasification fan when 2# gasification fan tripping or stopped.

Ash silo gasification fan system Operation mode: 1 in operation, 1 in standby

8.3.3

No.

Test item

(1)

1# Electric heater startup condition: gasification fan in operation

(2)

1# Gasification fan startup condition: fault free and remote

(3)


(4)

1# Gasification fan tripping, shutdown of electric heater

(5)

2# Electric heater startup Gasification fan is in operation

(6)

2#Gasification fan startup condition: fault free and remote

(7)


(8)

2# Gasification fan tripping, shutdown of electric heater

(9)

Enable interlocking to open outlet valve of 2# gasification fan and gives an alarm and start 2# standby gasification fan when 1# gasification fan tripped or stopped.

(10)

Enable interlocking to open outlet valve of 1# gasification fan and gives an alarm and start 1# standby gasification fan when 2# gasification fan tripped or stopped.

Fixed value

Results

Remarks

Results

Remarks

interlocked condition:2#

interlocked

Air compressor system for ash handling Operation mode: 2 in operation, 1 in standby No.

Test item

Fixed value

(1)

3# Air compressor started by interlocking when 1# and 2# compressor in operation but the pressure becomes low and interlocking enable.

又

(2)

2# Air compressor started by interlocking when1# and 3# compressor in operation but the pressure



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becomes low and interlocking enabled. (3)

8.3.4

1# Air compressor start by interlocking when 2# and 3# compressor in operation but the pressure becomes low and interlocking enabled.

Refrigerated type dryer system Operation mode: 2 in operation, 1 in standby

8.3.5

No.

Test item

(1)

3# Refrigerated air dryer start and its outlet valve opened by interlocking when 1# & 2# refrigerated air dryer in operation but any one of them stopped by fault.

(2)

1# Refrigerated air dryer start and its outlet valve opened by interlocking when 2# & 3# refrigerated air dryer in operation but any one of them stopped by fault.

(3)

2# Refrigerated air dryer start and its outlet valve opened by interlocking when 1# & 3# refrigerated air dryer in operation but any one of them stopped by fault

Fixed value

Results

Remarks

Fixed value

Results

Remarks

Ash silo discharging system No.

Test item

(1)

Startup condition of 1# feeder:1# Double shaft mixer is in operation

(2)

Opening condition of 1# pneumatic gate valve:1# feeder is in operation

(3)

1# Double shaft mixer tripping condition: water-break or overload protection action

(4)

1# Double shaft mixer tripping to shutdown feeder and pneumatic gate valve through interlocking

(5)

Startup condition of 2# feeder:2# Double shaft mixer is in operation

(6)

Opening condition of 2# pneumatic gate valve:2# feeder is in operation

(7)

2# Double shaft mixer tripping condition: water-break or overload protection action

(8)

1# Feeder and 1# Pneumatic flashboard stopped by interlocking when 2# Double shaft mixer tripped.

8.3.6

Programmed control test of ash removal system

8.3.6.1

Checklist of electric field #1 logic



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Inspection contents

No

Result

Initial status (condition) of electric field #1 under programmed control operation 01

Program control position of supervisory computer

02

Set local control box to program control position

03

Instrument air pressure is normal

04

Storage top ash pipe changeover valve is in operation

05

Bag type dust collector (heater) is in operation

06

Ash silo has no high level alarm

07

Feed sealing valve pressure is low

Feed sealing valve pressure low Confirm status of valves when electric field #1 system operation is stopped or at initial status 01

MD pump feed valve in close position

02

MD pump vent valve in close position

03

Transfer pipe discharge, gulp valve and secondary air valve are in close position

04

Feed sealing valve is closed

Flow of electric field #1 programmed control 01

Send programmed control start command

02

Confirm that programmed operation initial status (condition) is met

03

Confirm that the initial status of all valves is correct for the programmed control

04

Open feeding of all the MD pump inlet dome valves and air bleeding valves at the same time for the electric field

05

Feed for 3s. Any storage pump high level signal arrives or feed time is delayed by another 10s.

06

Close the feed of all the MD inlet dome valves and the air bleeding valves of the electric field (delayed by 5s)

07

Pressurize feed sealing valve (delayed by 3s) until inflation pressure is met

08

Open #1 electric field discharge valve (delayed by 4s)

09

Open transfer air valve, gulp valve and secondary air valve simultaneously (delayed by 20s)

10

Transfer pipe pressure low signal arrives

11

Close transfer air valve, gulp valve and secondary air valve simultaneously (delayed by 8s)

12

Close discharge valve

13

Re-enter the next cycle



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Electric field #1 transfer pipe clogged, program automatically goes to clogging removal cycle period 01

In case the pressure of transfer pipe in Item 10 within a cycle period is high, go to clogging removal cycle

02

Close transfer air valve, gulp valve and secondary air valve simultaneously

03

Transfer pressure is lower than 0.06MPa.

04

Close ash pipe pressure relief valve (delay by 3s)

05


06

Transfer pipe pressure low signal arrives; Otherwise, go back to Step 02 and then to clogging removal procedure again

07


08


09


10

In case transfer time exceeds 600s, give alarm, and the system will automatically reset. Manual clogging removal shall be carried out before carrying out programmed ash removal

8.3.6.2

Checklist of electric field #2 ash handling logic No

Inspection contents

Result

Initial status (condition) of #2 electric field programmed operation) 01


02

Set local control box to programmed control position

03


04


05


06


07


Confirm status of valves when electric field #2 system is shutdown or at initial status 01

MD pump feed valve is in close position

02

MD pump air bleeding valve is in close position

03


04


Flow of electric field #2 programmed control



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01


02


03

Confirm that the initial status of valves is correct for the programmed control

04


05

Feed for 3s. any storage pump high level signal arrives or feed time is delayed by another 10s.

06


07

Pressurize feed sealing valve (delayed by 3s) until inflation pressure is met

08

Open discharge valve (delay by 4s)

09


10

Transfer pipe pressure low signal arrives

11


12


13


Electric field #2 transfer pipe is clogged. The program goes automatically to clogging removal cycle period

8.3.6.3

01

In case the pressure of transfer pipe in Item 10 within a cycle period is high, go to clogging removal cycle period

02

Close transfer air valve, gulp valve and secondary air valve simultaneously

03


04


05


06

Transfer pipe pressure low signal arrives; Otherwise, go back to Step 02 and then to clogging removal procedure again

07


08


09


10


Checklist of electric field #3 ash handling logic


No.


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Inspection contents

Result

Initial status (condition) of #3 electric field programmed operation) 01


02


03


04


05


06


07


Confirm status of valves when electric field #3 is shutdown or at initial status 01

MD pump feed valve in close position

02


03


04




02


03


04


05

Feed for 3s. Any storage pump high level signal arrives or feed time is delayed by another 10s.

06


07

Pressurize feed sealing valve (delayed by 3s), inflation pressure is met

08

Depressurize discharge sealing valve (delayed by 5s), air pressure low is met

09

Open discharge valve (delayed by 6s)

10

Open transfer air valve, gulp valve and secondary air valve simultaneously (delay by 20s)

11

The condition that transfer pipe pressure low signal arrives is met

12

Close transfer air valve, gulp valve and secondary air valve simultaneously (delay by 8s)

13

Close discharge valve (delay by 5s)

又



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14

Pressurize discharge sealing valve. Air pressure high is met

15


Transfer pipeline of electric field #3 is clogged,. Program goes automatically to clogging removal cycle period 01

Go to clogging removal cycle period if transfer pipe pressure is high in Item 11 within a cycle period

02

Close transfer air valve, gulp valve and secondary air valve simultaneously and open ash pipe pressure relief valve

03


04


05


06

Transfer pipe pressure low signal arrives. Otherwise, go back to Step 02 and then to clogging removal procedure again

07


08


09


10


8.3.6.4

Checklist of electric field #4 ash handling logic No.

Inspection contents

Result

Electric field #4 programmed control initial status (condition) 01


02


03


04


05


06


07


Confirm status of valves when electric field #4 system is shutdown or at initial status 01


02


03



04


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02


03


04


05


06


07


08

Depressurize discharge sealing valve (delayed by 5s), air pressure low is met

09

Open discharge valve (delayed by 6s)

10


11

The condition that transfer pipe pressure low signal arrives is met

12

Close transfer air valve, gulp valve and secondary air valve simultaneously (delay by 8s)

13

Close discharge valve (delay by 5s)

14

Pressurize discharge sealing valve. Air pressure high is met

15


Electric field #4 transfer pipe is clogged. The program goes automatically to clogging removal cycle period 01

Go to clogging removal cycle period if transfer pipe pressure is high in Item 11 within a cycle period

02

Close transfer air valve, gulp valve and secondary air valve simultaneously and open ash pipe pressure relief valve

03


04


05


06


07


08


09



10

8.3.6.5


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Checklist of economizer ash handling logic No.

Inspection contents

Result

Economizer fly ash settler programmed operation initial status (condition) 01


02


03


04

Storage top ash pipe valve is in operation

05


06


07


Confirm status of valves when economizer fly ash settler is shutdown or at initial status. 01


02


03


04


Flow of economizer fly ash settler programmed control 01


02


03


04

Open the feeding of all the MD inlet dome valves of fly ash settler

05


06

Close the feeding of all the MD pump inlet dome valves of fly ash settler (delayed by 5s)

07


08

Open discharge valve of fly ash settler (delayed by 4s)

09

Open transfer air valve, gulp valve simultaneously (delayed by 20s)

10

Fly ash settler transfer pipe pressure low signal arrives



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11

Close transfer air valve and gulp valve simultaneously (delayed by 8s)

12

Close discharge valve (delayed by 2s)

13


Economizer fly ash settler transfer pipe is clogged. The program automatically goes to clogging removal cycle period 01

In case the pressure of transfer pipe in Item 10 within a cycle period is high, go to clogging removal cycle period

02

Close transfer air valve, gulp valve and open ash pipe pressure relief valve simultaneously

03


04


05

Open transfer air valve, gulp valve simultaneously (delayed by 20s)

06


07

Close transfer air valve and gulp valve simultaneously (delayed by 8s)

08


09


10

In case transfer total time exceeds 600s, gives alarm. System will reset automatically. Manual clogging removal shall be carried out before carrying out programmed ash removal

8.4

Checking of the interlocking and protection of deslagging system

8.4.1

Dry-type slag remover No.

Test item

Conditions for the dry-type slag remover start-up (1)

Set at “REMOTE”

(2)

No protective trip conditions

(3)

Slag crusher is already in operation

Interlock Protection and Alarm of Dry Type Slag Remover (1)

Chain break of slag remover, slag remover tripping, and alarm

(2)

Over-temperature of slag remover, slag remover tripping, and alarm

(3)

Slag crusher trip or shutdown by fault, slag remover shutdown, and alarm

(4)

Emergency button shutdown (local), tripping, alarm

(5)

Electrical protection actuation, tripping, alarm

Fixed value

Results

Remarks



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Slag crusher No.

Test item

Fixed value

Results

Remarks

Fixed value

Results

Remarks

Fixed value

Results

Remarks

Fixed value

Results

Remarks

Slag crusher startup condition (1)

Slag crusher set to remote

(2)


(3)

Bucket elevator is in operation

Slag crusher interlock protection and alarm (1)

Slag crusher locked, tripping, alarm

(2)

Slag crusher overload or electrical protection action, tripping, alarm

(3)

Emergency button shutdown (local)

8.4.3

Bucket elevator No.

Test item

Bucket elevator startup condition (1)

Bucket elevator is set to remote

(2)


Bucket elevator interlock protection and alarm (1)

Bucket elevator locked, tripping, alarm

(2)

Slag crusher overload or electrical protection action, tripping, alarm

(3)

Emergency button stop

8.4.4

Slag storage No.

Test item

(1)

Slag storage high level, alarm

(2)

Slag storage rapping (1, 2, 3) startup (local, remote)

(3)

Slag storage rapping (1, 2, 3) shutdown (local, remote)

8.4.5

Double shaft mixer No.

Test item

(1)

Startup condition of feeder: Double shaft mixer is in operation

(2)

Opening condition of pneumatic gate valve: The feeder is in operation



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(3)

Double shaft mixer tripping condition: water-break or overload protection action

(4)

Double shaft mixer tripping to shutdown feeder and pneumatic gate valve through interlocking

8.5

Deslagging system in operation and shutdown

8.5.1

Check to be completed prior to system startup

8.5.2

8.5.3

8.5.3

(1)

Confirm that the interlock test result for ash removal system is acceptable.

(2)

Make sure that all defects have been eliminated.

(3)

Make sure that all equipment have been energized.

(4)

Make sure that all kinds of instrument has been put into operation.

Putting the deslagging system into operation (1)

Slag storage is available with slag intake condition. Interlocking is put into operation.

(2)

Make sure that the bucker elevator meets its start-up condition and has been started with the speed well adjusted.

(3)

Make sure that the slag crusher meets its start-up condition and has been started.

(4)

Make sure that the dry-type slag remover meets its start-up condition and has been started with the speed well adjusted.

Stop operation of the deslagging system (1)

Stop the dry-type slag remover after revolution drop.

(2)

Stop the slag crusher.

(3)

Stop the bucker elevator after revolution drop.

Carry out combined commissioning of system equipment When the defects found in the startup and commissioning have been eliminated, restart the deslagging system equipment for combined operation.

8.6

Startup and shutdown of the ash removal system

8.6.1


8.6.2

(1)

Confirm that the interlock test result for ash removal system is acceptable.

(2)

Make sure that the programmable control for all fields of ash removal system has been tested for satisfaction.

(3)

Make sure that all defects have been eliminated.

(4)

Make sure that all equipment have been energized.

(4)

Make sure that all kinds of instrument has been put into operation.

Put the ash removal system into operation (1)

Preparing to put the ash removal system into operation after the boiler ignition.

(2)

Make sure that the ash silo meets the conditions to receive the ash.


8.6.3


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(3)

Make sure that the conditions for startup of bag ash collector and silo gasification fan have been met. Start them and make the interlocking enabled when they are running well.

(4)

Make sure that the conditions for startup of air compressor and refrigerated air dryer have been met. Start them and make the interlocking enabled when they are running well.

(5)

Make sure that the air pressure for instrument and ash removal meets the requirement.

(6)

Make sure that the conditions for startup of ash hopper gasification fan and electric heater have been met. Start them and make the interlocking enabled when they are running well.

(7)

Have the ash removed from the ash lines of all fields and economizer under the control of PLC program.

Stop the ash removal system (1)

After the boiler shutdown have the ash removal system operated for thirty (30) minutes and make sure that all hoppers have been emptied.

(2)

Stop the ash removal operation of lines of all fields and economizer controlled by PLC program separately.

8.7

Commissioning of electrostatic precipitator (ESP) system

8.7.1

Rapping test for cathode and anode plates

8.7.2

8.7.3

(1)

Have the motor of cathode and anodes ran for two (2) hours without load, check and eliminate the defects, such as abnormal temp. rise, vibration and/or noise if discovered.

(2)

Make the whole rapping system test, check and correct any bind-seize if discovered.

(3)

Check the rotation direction during the test and contrarotation is not allowed.

(4)

Start the line shafting of cathode and anode and press the emergency pushbutton when the motor has reached its full speed. If the line shafting does not run for one revolution, take the test run once again following the above procedures. If no any abnormality found, contact the electrical operator to switch it in for a continuous operation.

(5)

Have the equipment tested for one hour and then shut down for complete inspection and prepare to take the adjust of the rapping timing.

(6)

Follow the specified value by the manufacturer to adjust the rapping timing for cathode and anode for satisfaction to complete the test.

(7)

Round-off work: Have all motors de-energized and lock the local switch. Seal the hole for rapping shaft and clear up remaining foreign matters during the test operation.

Commissioning of the energized electric heater for ESP (1)

The AC withstand test and insulance measurement for the electric heaters hall be taken before commissioning with test voltage of 2,000 V and insulance not less than 50mΩ.

(2)

Make the electric heater energized and check if there is any short circuit existed and whether the range of temperature control was correct, and the temperature climbing speed.

ESP no-load boosting test Cooperate with the electrical specialty.



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8.7.4

Handling of coherent ash before putting the ESP into operation

8.7.5

Conditions for operation of ESP (1)

Putting the heating devices for insulators and rapping porcelain shaft housings for the discharge electrodes and ash hoppers into operation twelve (12) hours ahead of the boiler ignition.

(2)

No operation of any field of ESP permitted when the oil is taken as the only fuel for the boiler, and the rapping equipment needs to be ran continuously.

(3)

When the first set of coal pulverizing system entering a normal operation, put the ESP’s fields into operation one by one according to the PLC’s program and have the rapping equipment changed to periodical operation provided the following on-site conditions are met: The burners have been atomized well and have satisfied ignition; The waste-gas temperature is higher than 110℃; No dark smoke discharged from the chimney.

8.7.6

Shutting down of the ESP (1)

Stop operation of ESP’s fields one by one and have the rapping equipment of them changed to continuous operation under the following conditions: Coal and oil co-fired during the period of the boiler shutting down; The waste-gas temperature is lowered to 110℃.

8.8

(2)

All fields have to be stopped when the oil is used as the only fuel of the boiler.

(3)

After the induced draft fan (IDF) stopped keep a continuous operation of the rapping equipment to empty the ash hoppers. Stop operation of all heaters.

System operation at the stages of the whole set start-up Have the system’s reliability tested in different operation stages of no load, partial load, full load and thirty (30) days continuous operation.

9.

Safety Measures

9.1


9.1.1

The parties participating in the commissioning will be ware of and observe relevant safety regulations on the site, wear proper clothes and personal safety protection articles.

9.1.2


9.1.3


9.1.4


9.2


9.2.1

Rotating equipment



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Injuries might be caused by rotating equipment during commissioning or test. Therefore, special care must be taken during work and do not touch the rotating components with tools or your hand. 9.3


9.3.1

Emphasis shall be put on the monitoring of bearing temperature, bearing bush vibration, and motor coil temperature during test run of auxiliary equipment to avoid temperature and vibration exceeding the allowable limit. Stop the operation of equipment as necessary.

9.3.2

Before opening the feed valve of ash discharging pump of the ash silo, the sundries within the buckets and the feed pipe must be removed manually to avoid entering the storage pump causing clogging of the gasification holes of the pump and seizing the feed and discharge valves.

9.3.3

Check the ash silo and remove the inside sundries to guarantee that the fluidizing holes of the fluidizing plate are not blocked.

9.3.4

Check the deslagging system before commissioning to guarantee there are no large sized sundries causing damage to equipment.

10.

Appendix


10.1


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Appendix 1 Commissioning Condition Checklist No.

Items

Requirements

Result

1

Erection work of system and its equipment

All fulfilled

□Yes □No

2

Foreign materials inside the system and its equipment

Clean up

□Yes □No

3

Test operation for each equipment separately

Eight-hour test operation finished and all defects eliminated.

□Yes □No

4

Ventilation test

Test finished and defects eliminated.

□Yes □No

5

Ash silo dried by ventilation

Forty eight-hour aeration-drying finished.

□Yes □No

6

Checking of pneumatic and hand -operated valves by operating (opening / closing)

The indication conforms to the real position.

□Yes □No

7

All ash conveying pipelines

Purged by air pressure test.

□Yes □No

8

Thermodynamic instrument, level gauges, pressure switches, etc.

Commissioning is finished, can be put into operation

□Yes □No

9

All safety valves of the system

Completely equipped and calibrated for satisfaction.

□Yes □No

10

Programmed control system

Commissioning finished and have a correct logic relationship.

□Yes □No

11

Interlock and audio & visual alarm device

Commissioning finished and tested for satisfaction.

□Yes □No

12

Field condition

Clear road, sufficiency of illumination.

□Yes □No

13


Sufficient for use and performance is reliable.

□Yes □No

14

Fire apparatus


□Yes □No

15


All categories with sufficient quantities.

□Yes □No

16

Tools and instrument for commissioning

Prepared

□Yes □No


Date:

Date:


Dongfang Electric: Date:

Date:

Date:

Verifie d by

Rem arks


10.2


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Appendix2 Valves Commissioning Record Valves Commissioning Record C Remote Local position indication

KKS code

Name

10ETG11AA701

FIRST FIELD NO.1 CONVEYER HOPPER INTAKE VALVE

10ETG12AA701


10ETG13AA701


10ETG14AA701


10ETG10AA701

FIRST FIELD NO.1 CONVEYER HOPPER TRANSPORTATION INFLOW VALVE OPEN COMMAND

10ETG12AA701

SECOND FIELD NO.1 HOPPER INTAKE VALVE

CONVEYER

10ETG22AA701


CONVEYER

10ETG23AA701


CONVEYER

Directi on

Feed back


Off(Clos e)

Date

Result

Signat ure

Remarks



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10ETG24AA701


CONVEYER

10ETG20AA701

SECOND FIELD NO.1 CONVEYER HOPPER TRANSPORTATION INFLOW VALVE

10ETG31AA701

THIRD FIELD NO.1 CONVEYER HOPPER INTAKE VALVE

10ETG32AA701


10ETG33AA701


10ETG34AA701


10ETG30AA701

THIRD FIELD NO.1 CONVEYER HOPPER TRANSPORTATION INFLOW VALVE OPEN COMMAND

10ETG41AA701

FOUR FIELD NO.1 CONVEYER HOPPER INTAKE VALVE

10ETG42AA701


10ETG43AA701




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10ETG44AA701


10ETG40AA701

FOUR FIELD NO.1 CONVEYER HOPPER TRANSPORTATION INFLOW VALVE

10ETG20GC001

SECOND FIELD VALVE

PIPE OUTFLOW

10ETG20GC002

THIRD VALVE

PIPE

10ETG60AA002

GASIFICATION VALVE

FAN

NO.1

OUTLET

10ETG60AA004

GASIFICATION VALVE

FAN

NO.2

OUTLET

10ETG20AA007

TOP OF FLY ASH SILO SWITCH TO 2# FLY ASH SILO VALVE 1

VALVE

10ETG10AA007


VALVE

10ETG10AA008


VALVE

00ETP10AA002

1# SCREW AIR COMPRESSOR OUTLET VALVE

00ETP10AA010

1# REFRIGERATED AIR DRYER INLET VALVE

FIELD

OUTFLOW



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00ETP10AA011

1# REFRIGERATED AIR DRYER OUTLET VALVE

00ETP10AA005


00ETP10AA015


00ETP10AA016


00ETP10AA008


00ETP10AA020


00ETP10AA021


10ETG51AA001

ECONOMIZER NO.1 HOPPER INTAKE VALVE

CONVEYER

10ETG52AA001


CONVEYER

10ETG53AA001


CONVEYER

10ETG54AA001


CONVEYER


10ETG50AA001

Owner

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ECONOMIZER NO.1 CONVEYER HOPPER TRANSPORTATION INFLOW VALVE

Commissioning Contractor: Contractor:


Date: Date:


Date:

Date: Date:



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-M-01-LB-001


CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY DETAIL

SiChuan Electric Power Commissioning &

PLTU 1 Jatim-Pacitan (2×315MW)

Test Institute

Project

Approval

Check

Review

Design

Date

Scale

DESIGN STAGE

Procedure of Boiler Steam Blowing N/A

DWG No.


REV

A


Procedure of Boiler Steam Blowing

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PURPOSE .................................................................................................................................... 3

2.

SCOPE ......................................................................................................................................... 3

3.

PREPARATION BASIS............................................................................................................... 3

4.

GENERAL DESCRIPTION OF SYSTEM AND EQUIPMENT ................................................ 3

5.

TOOLS, INSTRUMENT FOR COMMISSIONING ................................................................... 4

6.

PREREQUISITE FOR COMMISSIONING ............................................................................... 4

7.

MEASURES FOR COMMISSIONING ORGANIZATION ..................................................... 10

8.

BLOWING FLOW..................................................................................................................... 12

9.

BLOWING PARAMETERS AND THE QUALIFIED STANDARD ....................................... 12

10.

TEMPORARY FACILITY FOR BLOWING ............................................................................ 14

11.

PREPARATION PRIOR TO IGNITION ................................................................................... 15

12.

TEMPERATURE RISING AND PRESSURE RISING FOR BOILER IGNITION.................. 25

14.

SAFETY MEASURES .............................................................................................................. 31

15.

APPENDIX................................................................................................................................ 36

Appendix 1

Blowng condition checklist.......................................................................................... 37

Appendix 2

Record list for blowing acceptance............................................................................. 45

Appendix 3

Record Table for Blowing Parameters ....................................................................... 46

Appendix 4

Blowing Diagram ......................................................................................................... 47

Appendix 5 Blowing Diagram for Desuperheating water Pipeline of SuperHeater or Reheater ............................................................................................................................................................... 48 Appendix 6

Processing Diagram of Grain Collector ..................................................................... 49

Appendix 7

Checklist for Motorized Valve of Steam-Water System............................................ 50

Appendix 8

Checklist for Control Valve of Steam-Water System ................................................ 55


1.


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Purpose The procedure of boiler steam blowing will be employed to blow away the foreign matters remained in the such systems as the boiler superheater, reheater and steam pipeline to ensure the safe and economic operation of the unit.

2.

Scope This procedure is applicable for the commissioning of steam blowing of the unit, the blowing scope covers:

2.1

The boiler superheater system and the main steam pipeline;

2.2

The boiler superheater system, the reheating pipeline at cold section and the reheating pipeline at hot section;

2.3

The main steam desuperheating water pipe and desuperheating water pipeline for the reheater

2.4

The high pressure bypass pipeline of steam turbine

2.5

The gas source for the shaft seal of steam turbine and other pipelines at the steam turbine side

3.

Preparation Basis

3.1

The diagram for boiler burning and coal pulverizing system;

3.2

The thermodynamic system diagram for the whole boiler plant;

3.3

Boiler Product Manual;

3.4

Manual for Boiler Installation

3.5

Manual for Boiler Operation

4.

General Description of System and Equipment

4.1

The model of boiler: DG1025/18.3-II13, natural circulation brown coal-fired drum boilers with single tangentially fired furnace (at four-corner), Type II arrangement in open air, reheat system and balanced draft.

4.2

Temperature regulating mode: the water spray desuperheating is employed for the superheating steam, swaying of the burner nozzle is taken as the principal for the reheating steam and micro regulating by water spray is assisted.

4.3

The model of the coal mill is HP963; five coal mills are provided for each boiler (when the coal is designed for burning, four operating and one standby).

4.4

The arrangement and type for the burner: four-corner arrangement is employed; the centerline of the four-corner mounted burner is tangent with two imaginary circles the centerline of the furnace respectively; the diameters for two imaginary circles are ф548mm and ф1032mm respectively.

4.5

Main parameters of the boiler: Unit Main steam

BMCR

TMCR

TRL

75%TRL

50%TRL

Flow

T/h

1025

976.19

927.8 0

678.00

467.50

Pressure

MPa

18.0

17.5

17.33

14.33

9.56

Temperature

℃

541

541

541

541

535


Reheat steam


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Flow

T/h

863.7

802.023

766.0 1

571.00

402.08

Inlet pressure

MPa

3.99

3. 625

3.54

2.66

1.85

Outlet pressure

MPa

3.80

3.438

3.38

2.53

1.76

Inlet temperature

℃

329

322

320

313

318

Outlet temperature

℃

541

541

541

541

515

℃

281

275.5

273

255

234

Temp. of feed water

5.

Tools, Instrument for Commissioning

5.1

Walkie-alkie；

5.2

Handheld vibration meter；

5.3

Temperature measurement meter；

5.4

Pressure gauge。

6.

Prerequisite for Commissioning Prior to system commissioning, the commissioning personnel shall perform complete inspection upon the prerequisite for system commissioning according to Appendix 1 (Commissioning Condition Checklist) and enter the result of check on records accordingly.

6.1

Conditions that must be available with machinery provisions

6.1.1

Temporary pipeline system for blowing

6.1.2

(1)

Completion on installation and heat insulation of the temporary pipeline (including such work as drainage and heat insulation);

(2)

Completion on installation and commissinoing for the temporary motorized valve, bypass valve and drainage valve;

(3)

Completion on fabrication and installation for target device, with sufficient target;

(4)

Being qualified for on/off test of the motorized valve and the test for the lighting and signal

(5)

Completion and qualification on installation of the counter-force support and fixing and sliding hanger for the temporary pipeline;

(6)

Completion on fabrication and installation of the grain collector;

(7)

Completion on installation and calibration for the pressure gauge and thermometer installed for the temporary system of blowing.

Flue-gas and air system (1)

The air pressure test of boiler is completed and qualified through acceptance.

(2)

Completion on installation and heat insulation for boiler proper as well as flue-gas and air duct


6.1.3

6.1.4

6.1.5

6.1.6


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(3)

Completion on single commissioning for IDF, FDF, primary fan and air preheater and commissioning of subsystem;

(4)

Completion and qualification on inspection and adjusting for each damper and baffle

Flame detecting system (1)

Completion on single commissioning of the cooling fan and interlock protection test as well as qualification on acceptance

(2)

Qualification on static commissioning for flame scanner;

(3)

The commissioning of the CCTV system is complete and it can be put into operation at any time.

(4)

Qualification on commissioning for the flue-gas temperature probe of the boiler;

Electrostatic precipitator system (1)

Completion on installation and heat insulation for electrostatic precipitator as well as qualification on acceptance;

(2)

Qualification on air distribution test as well as pressure rising and vibration test for the electrostatic precipitator

(3)

Completion on installation for heating device of dust hopper for the electrostatic precipitator and qualification on inspection and acceptance

Fuel oil system (1)

Completion on installation and heat insulation for oil storage and boiler fuel oil system and completion on single commissioning;

(2)

Completion on water pressure test for the boiler fuel oil system and qualification on being flushed by water and being blown by steam;

(3)

Completion on installation and blowing for steam blowing pipeline of fuel oil system as well as completion on commissioning for each blow down valve

(4)

Completion on commissioning for each motorized and pneumatic valve of fuel oil system as well as qualification on acceptance;

(5)

Qualification on simulation test for each interlock protection (MFT and OFT) of fuel oil system;

(6)

Completion on extending and withdrawing test for each oil gun and high-energy igniter;

(7)

Completion on static commissioning for each flame check

Boiler proper (1)

Completion on installation and heat insulation for boiler proper as well as qualification on acceptance;

(2)

Completion on water pressure test of boiler and qualification on acceptance;

(3)

Completion on installation and heat insulation for such systems as drainage, air vent, regular discharging, continuous discharging, bottom heating and nitrogen charge and completion on commissioning for each motorized valve as well as qualification on acceptance;

(4)

Installation for water pressure block plate of the main steam pipeline at oulet of the superheater is completed to be applicable for the water pressure prior to ignition of boiler;


6.1.8

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(5)

After the water pressure test, the valve cores of water pressure for each safety valve of drum and superheater are removed to restore to formal conditions and meet the requirement of manufacturer. The water pressure block plate of steam and water system should be removed.

(6)

The spring hangers for each steam and water pipeline are complete and perfect and pins are removed so that they are in conditions of free-bearing capacity.

(7)

Qualification on commissioning for the motorized and pneumatic valve for each steam and water pipeline;

(8)

The parties inspect expansion system for boiler proper jointly to conform that there is free of barrier and expansion; each expansive indicators should be complete and be adjusted to zero;

(9)

The ladders, platforms and the handrails of the boiler proper should be complete, the illumination should be sufficient; the boiler proper should be clean;

(10)

After completion of pickling for the boiler, the inner of drum should be clean, the inner devices should be returned to normal, the drum should be sealed, the temporary facilities should be removed and the formal system has been restored.

(11)

The water level gauge of the drum should be installed properly; the commissioning for water level through CCTV system is completed and can be put into operation at any time.

(12)

The sampling and dosing devices for the boiler water are installed properly and qualified through inspection.

(13)

The installation and heat insulation work for water supply, desuperheating water and the emergency water spray system are completed; they are qualified through water washing; the commissioning for the motorized and pneumatic valves is completed. The installation and heat insulation for the temporary back-washing pipeline of the desuperheater are completed; the qualification is made via inspection and confirmation.

(14)

Each manhole door and inspection hole door for the boil body should be complete and sealed.

(15) 6.1.7


The cold inspection for installation of the boiler burner and the cold commissioning for coal flame check are qualified as well as are ready for use.

Deashing system (1)

The installation for the slag pit at the bottom of boiler (including the wind seal at the bottom of boiler), slag depot and the rotary equipment is completed and is qualified through acceptance.

(2)

The commissioning for each single equipment of deslagging system is completed, the on/off test for the hydraulic shut-off valve is qualified and they are ready for use.

(3)

The installation and commissioning for dedusting system equipment are completed; the commissioning for dedusting programmed logic is completed; they are ready for use.

Coal handling system (1)

Completion on equipment installing and commissioning for each single equipment as well as qualification on acceptance

(2)

Qualification on interlock protection test of system

(3)

The defects found during the system commissioning are removed, the coaling condition is provided.


6.1.10

6.1.11

6.1.12

6.1.13

61.14


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Soot blower system (1)

Completion on installation and heat insulation for boiler proper, soot blower of convection funnel and pipeline;

(2)

Completion on installation and commissioning for the motorized and pneumatic valve on the pipeline for the steam source of soot blower;

(3)

After completion for soot blowing operation test of air preheater, it can be put into use at any time.

Coal pulverizing system (1)

Completion on installation of coal pulverizing system and heat insulation

(2)

Qualification on trial run of the seal fan;

(3)

Qualification on primary air leveling for pulverizing system;

(4)

Qualification on calibration of airflow at the inlet of coal mill;

(5)

Completion on commissioning for lubrication system of coal mill;

(6)

The commissioning for coal mill and coal feeder is completed; the operation condition is provided;

(7)

Completion on transmission test for all the baffles and dampers

(8)

Qualification on calibration for weighing device of coal feeder

Air heater system (1)

Completion on installation and heat insulation

(2)

The single commissioning is completed and it is ready for use;

(3)

Qualification on interlock protection test for system

Compressed air system (1)

Completion on single and sub-system commissioning for instrument and service air compressors;

(2)

Completion on installation for instrument and service air tanks and qualification on calibration of safety valve;

(3)

Qualification on blowing for instrument and service air pipelines;

(4)

Qualification on interlock protection test for system

Fire fighting system (1)

Completion on installation of firefighting system

(2)

Completion on each firefighting facility and qualification on water draining test and being standby state

(3)

Completion on the firefighting appliances in the control room, electric room and fuel oil system

Industrial water system (1)

Completion on installation of industrial water system and qualification on water pressure test

(2)

After the trial run for the industrial pump and the industrial water subsystem is



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completed, the operation can be made at any time. 6.1.15

Auxiliary steam system (1)

After the installation and commissioning for the boiler are completed, it can be put into service.

(2)

Completion on installation and heat insulation for each auxiliary steam system

(3)

After the qualification for the motorized valve for the auxiliary system is confirmed, the operation can be made.

6.1.16

Isolation between relevant utilities and 2# unit

6.1.17

Chemical water preparation system

6.1.18

(1)

The chemical water system is provided with the condition of continuous water supply.

(2)

Completion on trial run for water charging system

Requirement for steam turbine discipline (1)

The condenser and hot water well are qualified through cleaning; the condensing pump is qualified through trial run; the system is qualified through flushing; the water supply can be made towards the deaerator;

(2)

After the inner of the deaerator is clean and flushed with water and the steam heating pipeline is blown, it resumes to normal conditions and the heating and the operating conditions are provided;

(3)

The trial run for the electric feed water pump is qualified; the feed pipeline is qualified by flushing of the entire system; it resumes to normal conditions and has ready for normal operation. ;

(4)

Various measures to prevent steam from entering the turbine have been taken and the qualification of acceptance has been made through inspection;

(5)

The commissioning work for the vacuum system of steam turbine is completed and the normal operation conditions are provided;

(6)

The commissioning work for lubrication oil, sealing oil and jacking oil system for the steam turbine is completed; the turning system is ready for normal operation;

(7)

The main steam pipeline of steam turbine, reheating system and the high and low pressure bypass drain valve are confirmed to be qualified and can be put into operation;

(8)

After commissioning and inspection for the temperature measuring points of the steam turbine cylinder are completed, the temperature of the cylinder can be shown correctly;

(9)

Each electric steam extraction interception valve is confirmed to be qualified and closed strictly;

(10)

The drainage for each condenser introduced is isolated reliably;

(11) The spray for low-pressure cylinder can be put into operation. 6.2

Conditions that must be available with electrical and I&C (1)

The static test for boiler FSSS (fuel oil and coal feeding part) is completed, including: 1)

Completion on interlock test for flame check cooling fan;

2)

Completion on inspection and test for blowing condition of furance;


(2)


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3)

Completion on MFT test and the interlock test after MFT;

4)

Completion on OFT test of fuel oil and the interlock test after OFT;

5)

Completion on fuel oil leakage test;

6)

Completion on combustion management system for each oil gun;

7)

Completion on control and interlock test for coal feeder and coal mill;

Completion on sequence control, interlock and protection test (SCS part) of auxiliaries, including: 1)

Start conditions, trip conditions, programmed start and programmed stop for air preheater ( A/B);

2)

Start conditions, trip conditions, programmed start and programmed stop for induced air fan (A/B);

3)

Start conditions, trip conditions, programmed start and programmed stop for forced draft fan (A/B);

4)

Start conditions, tripping conditions, programmed start and programmed stop for primary air fan (A/B);

5)

Start conditions, trip conditions, programmed start and programmed stop for primary air fan (A/B/C/D/E);

6)

Start conditions, trip conditions, programmed start and programmed stop for coal feeder (A/B/C/D/E);

7)

Start conditions, trip conditions for sealing fan (A/B);

(3)

The static test for DAS system is completed; the installation for the temperature measuring points of each metal wall of heating face for boiler is completed and qualification is made through cold state inspection and acceptance as well as the original record has been made by the professionals; the project commissioning work related to DAS system and blowing work is completed, with accurate and reliable indication, such as: pressure of drum, superheater, reheater, steam temperature, wall temperature, water supply pressure, temperature, water supply flow, electric contact water level gauge, furnace flame CCTV, negative pressure meter of furnace, flue-gas temperature probe of furnace, secondary air, air flow of primary air, air pressure and temperature, steam water and the flue-gas and air system as well as other measuring points of all I&Cs, fuel pressure, fuel temperature, air flow meter, current of each auxiliary device, temperature of bearing and vibration of bearing. All above must be put into operation properly.

(4)

The commissioning and transmission for various protection, alarm and acoustic and light signals of alarm window are completed and the normal alarm can be made.

(5)

The safety power supply is ready for use.

(6)

The two- way power supply for DCS can be put into service normally.

(7)

The control chart for the steam blowing system of unit is drawn from DCS. DAS system is used for the data acquisition during blowing; prior to ignition of boiler, such works as the system connection, parameters configuration and print commissioning are completed according to the parameters listed in the table below. Drum pressure

Pressure ucpstream of grain collector

Pressure for superheated steam

Temperature upstream of grain collector


6.3

6.4

7.


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Inlet pressure for reheated steam

Pressure downstream of grain collector

Outlet pressure for reheated steam

Exhaust steam pressure for the temporary pipe

Temperature of superheated steam

Exhaust steam temperature for the temporary pipe

Reheat steam temperature

Feed water flow

Conditions that must be available with civil construction (1)

The roads within the commissioning site must be free of obstructions. There is adequate lighting and reliable emergency illumination。

(2)

The communication equipments on the commissioning site are convenient and available to guarantee the communication is smooth. There are sufficient fire fighting appliances.

(3)

After the air conditioning system is debugged properly, it can be put into operation to meet the requirement of computer equipments.

(4)

After the installation and commissioning for the elevator of boiler is completed and qualified via acceptance, it can be put into use.

Other conditions required (1)

The joint inspection is organized for such related aspects as the construction, building, Owner, production and commissioning and the problems found should be solved completely. The ignition condition is confirmed to be provided.

(2)

The preparation for the production commissioning is completed and the operators are provided in completeness and qualified via the training and examination. The operation regulation and the system diagram are reviewed; the operation tools are prepared reasonably and the operation log is prepared properly.

(3)

The chemicals and materials for commissioning are prepared properly; the sufficient chemical water, fuel and fire coal in compliance with the design requirement should be prepared.

(4)

The maintenance tools and materials required are prepared.

(5)

The command and organizing system for trial run is perfect and the division of work is defined clearly.


7.1



◆


◆



7.2

7.3

7.5

7.6

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◆


◆


◆


◆




◆


◆


◆


◆

Be responsible for temporary coordination of local control and instruments and connection terminals.;

◆

Be responsible for the fabrication and installation for target board and grain collector;

◆

Be responsible for the isolation work and the temporary listing work for relevant systems and equipments


7.4



Responsibilities of Operation Department ◆


◆


◆


◆


◆


Responsibilities of Dongfang Electric Corporation ◆


◆


◆


◆


Responsibilities of Project Owner ◆




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◆


◆


8.

Blowing flow

8.1

The blowing flow for the boiler superheater, main steam pipeline, reheater and reheating pipeline at the hot and cold section is as follows: Drum--->superheater---> main pipeline of the main steam pipe---> branch pipeline of the main steam pipe---> main steam valve (adding the block plate) --->leading out of temporary branch pipe---> motorized valve for temporary blowing control --->temporary pipe---> reheating pipeline at cold section (adding the grain collector at the boiler side) ---> reheater ---> reheating pipeline at hot section ---> branch pipe in front of combined intermediate valve---> combined intermediate valve (added with the block plate) ---> leading out of temporary branch pipe---> temporary pipe ---> target board machine ---> temporary pipe ---> to atmosphere via muffle

8.2

The blowing flow for HP bypass system is as follows: Drum--->superheater---> main pipeline of the main steam pipe---> HP bypass pipeline---> motorized valve for temporary control of HP bypass blowing ---> HP bypass pipeline --->reheating pipeline at cold section (adding the grain collector) ---> reheater ---> reheating pipeline at hot section ---> branch pipe in front of combined intermediate valve---> combined intermediate valve (added with the block plate) ---> leading out of temporary branch pipe---> temporary pipe ---> target board machine ---> temporary pipe ---> to atmosphere via muffle

8.3

Blowing flow for desuperheating water system of superheater and reheater (with reference to Appendix): The flow-measuring device for the first, second and third stage desuperheating water system of superheater is not installed temporarily, which is disconnected at the location of control valve (removal of the control valve) and led out by employing the temporary pipeline respectively to perform blowing and flushing with the steam and water supply for at steam side and water side. The blowing pressure at steam side of the superheater is around 3.0MPa(Blowing for 5 times and 5 minutes once). The waterside flushing can be performed after the water supply pump is started until clear water is drained through blowing. The reheater steam side is blown with the main steam system simultaneously.

8.4

Blowing flow for the main steam system of feedwater pump turbine is as follows: Drum--->superheater---> main steam pipeline---> HP main steam valve of feedwater pump turbine---> temporary pipe blowing ---> steam exhaust (blowing completion for steam turbine)

8.5

Blowing for the steam source for the steam turbine shaft seal and other pipeline at the steam turbine side: The content refers to the blowing commissioning procedure at the steam turbine side. The boiler of this project is completed in combination with the steam turbine.

9.

Blowing parameters and the qualified standard

9.1

Blowing parameters: The pressure of drum is 5.5~ 6.5MPa and the temperature of main steam is 350℃~450℃ for the blowing of the main pipeline (the specific parameters are determined in conformity with the blowing coefficients from calculation during the process of the actual blowing). The temporary control valve should be opened and the temporary control valve should be closed at the 3.8~ 4.5Mpa of drum pressure. When the control valves are closed fully, the temperature reduction for the saturation temperature of drum is not greater than 42℃.



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The blowing parameters are determined as follows according to the blowing coefficient greater than 1.0: When the temporary control valve is open, refer to the table below for pressure of drum: pressure of drum (MPa)

System Description Main reheating steam system

Trail blowing 3.0

3.5

Formal blowing

Target

6.0

6.0

4.0

High pressure bypass system

3.0

4.0

-

Steam system for miscellaneous for steam turbine and feedwater pump turbine

2.0

3.0

3.0

Steam temperature：for formal blowing, the temperature is 380~ 450℃; for trail blowing, the temperature is above 350℃, the exhaust steam temperature is above 180℃. When the temporary control valve is closed, refers to the table below for pressure of drum: pressure of drum (MPa)

9.2

Pressure of drum at the time of starting (MPa)

Pressure of drum at the time of closing (MPa)

3.0

1.6

3.5

1.8

4.0

2.1

4.5

2.4

5.0

3.5

5.5

3.8

6.0

4.0

6.5

4.2

Criteria of acceptance： Under the condition that the blowing coefficient is greater than 1, the maximal grain diameter with the spot impacted on the target board is not greater than 0.5mm, in addition, when the number of visible spots ( 0.2~0.5mm) is not more than 5, twice continuous blowing are deemed as to be qualified. What’s more, the number of spots for the second target board should be less than that of the first. The inspection target board is copper board or the aluminum board. The calculation formula for the blowing coefficient is as follows: Steam flow at blowing 2×steam specific volume at blowing Steam flow under rated load2×steam specific volume under rated load



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10.

Temporary facility for blowing

10.1

The special -purpose block plate provided by the manufacturer of the steam turbine will be used to isolate the HP main steam valve from leading to the steam turbine side and led out temporary pipe from the valve cap and the temporary control motorized valve is added. The temporary pipeline is unblocked with the reheating pipeline of cold section at downstream of HP exhaust check valve (If the HP exhaust check valve is not installed, this position is disconnected.)

10.2

The treatment for the intermediate pressure main steam valve is identical to the one of the high-pressure main steam valve.

10.3

The high-pressure bypass valve is not installed; the temporary electric check valve is installed additionally to control blowing.

10.4

The low-pressure bypass valve is disconnected before entering into the condenser, the original valve is not installed, and the temporary pipe is led to the main exhaust steam pipe or the low-pressure bypass valve is not purged, the manual clearing mode is employed for the installation.

10.5

At the straight pipe section of the main exhaust pipe, the target board device is installed additionally.

10.6

The muffler is added at the exhaust, the installation for the muffler refers to the installation of muffler from the manufacturer as well as the operation and maintenance manual. The resistance pressure of muffler is not greater than 0.2MPa.

10.7

The flow device within the scope of blowing is not installed and connected with the short pipe with identical materials and pipe diameter.

10.8

For the temporary pipe purged, except for the pipeline from the target device of the main exhaust pipe to the muffler, the full bottoming with the argon arc welding is made. The sand blasting treatment is made prior to the installation of temporary pipe. The inner of the entire pipe should be clean and inspected by the quality control personnel.

10.9

When blowing the temporary pipe, the secure and reliable supports and hangers should be installed; and the heat expansion of pipeline and the airflow counter-force for blowing should be taken into account.

10.10

The temporary heat insulation is required to be made for the temporary pipe purged.

10.11

At each lowest point for the temporary blowing system, the drain pipeline and the drain valve are installed; the drainage is drained up to the safety place.

10.12

Such drain pipelines as the main steam, reheat steam (at cold and hot section) and HP and LP bypass pipelines are disconnected with the drain flash tank and the temporary special-purpose drainpipe is connected to discharge to atmosphere.

10.13

The temporary control valve for blowing should be maintained properly and provided with the stop function at the intermediate random position. The operation switch for the temporary valve should be led to the appropriate location of the concentrated control room. In order to heat the pipe and protect the temporary valve, the temporary valve should be provided with the bypass valve (PN>10Mpa, DN=89，t>450℃).

10.14

On the cold section pipe at inlet of the reheater, the grain collector should be added in parallel; at front and back of grain collector, a pressure gauge with 0~2.5MPa should be installed respectively. Requirement for the technical parameters of the grain collector: (1)

The pressure is greater than 3.0MPa; the temperature is greater than 450℃；

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure (2) 10.15


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Refers to the attached diagram for the constructional diagram.

Requirement for the technical parameters of the motorized valve controlled temporarily: (1)

Dg=300、Pg≥16.0MPa, T>450℃；

(2)

Fully open/close time should be less than 60 seconds uniformly;

(3)

It can be stopped at the intermediate random location

(4)

Welding the single- gate valve

10.16

Selection principles for the temporary pipeline

10.16.1

The cross section of the temporary pipeline should be greater than or equal to the one of the upstream pipeline.

10.16.2

Selection of the wall thickness: (1)

The design pressure for the temporary pipeline at the upstream of temporary control valve is P>10.0Mpa and t≥450℃；

(2)

The design pressure for the temporary pipeline from the downstream of the temporary control valve to the HP exhaust check valve is P>4.0Mpa and t≥450℃；

(3)

The design pressure for the temporary pipeline from the intermediate united valve to the exhaust steam pipe is P>1.6 Mpa and t≥450℃；

(4) 10.17

Design pressure for the main exhaust pipe is P>1.5Mpa and t≥450℃。

Specification for the target: (1)

Material: aluminum

(2)

Length: inner diameter for the longitudinal running through pipeline;

(3)

Width: 8% of length;

(4)

Thickness: 7mm；

(5)

Quantity:60 pieces。

Requirement for processing: the grinding and polishing treatment must be conducted for the surface of the entire targets. 10.18

On the temporary pipe near the exhaust, a piece of pressure meter with 0~0.6MPa and a piece of thermometer with 0~500℃ are installed and introduced into DCS system.

10.19

The mechanical treatment for the pipelines that cannot be participated into blowing should be executed, such as the steam lead pipe of the steam turbine or the LP bypass pipeline.

10.20

After blowing is completed, the pipeline is restored and the reliable measures must be taken for avoiding the secondary pollution.

11.

Preparation prior to ignition

11.1

Cold state inspection and transmission for the valve

11.1.1

Inspect and accept the electric or pneumatic switch valve as well as record the data below: Inspect whether KKS code, designation, local position indications, remote operation direction (as well as feedback are correct; the time for valve on/off, test date and signature of person in charge of test. Refer to Appendix 7 for other contents.

11.1.2

Inspect and accept the electric or pneumatic control valve as well as record the data below:



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Inspect whether KKS code, designation, local position indications and feedback indications corresponding to upward command of 0%, 50%, 75%, and 100% and downward command of 100%, 75%, 50%, and 0% respectively, test date, signature of person in charge of test. Refer to Appendix 8 for other contents.. 11.2

Inspection for interlock protection and alarm (note: the interlock protection test is based on the result of discussion on logical.)

11.2.1

The device power supply shall be located at the test location to inspect the items below: (1)

Start equipment through the computer and feedback on the computer is correct;

(2)

Stop equipment through the computer and feedback on the computer is correct;

(3)

Emergency button operates reliably

11.2.2

The interlock protection test for the boiler MFT (OFT) refers to the relevant contents in the whole set of commissioning procedure and fuel commissioning procedure.

11.2.3

The interlock protection test for the pulverizing system refers to the relevant contents in the commissioning procedure of pulverizing system.

11.2.4

The interlock protection test for the steam and water system covers: No.

Test item

Fixed value

Result s

1#and 2# recirculation motorized valves for boiler economizer (1)

After 2# recirculating motorized valve is closed , 1# recirculation motorized valve is closed by means of interlock

(2)

After 2# recirculating motorized valve is opened , 1# recirculating motorized valve is by means of interlock

Boiler Steam pressure protection test

(1)

When the steam pressure of the steam header is greater than 18.07Mpa, the ERV electromagnetic pressure release valve is opened automatically to relieve the pressure

(2)

When the steam pressure of the steam header is less than 17.6Mpa, the ERV electromagnetic pressure release valve shall close automatically.

Boiler superheated steam header starting the1#and 2# exhaust motorized valve (1)

After 2# exhaust motorized valve is closed , 1# exhaust motorized valve is closed by means of interlock

(2)

After 2# exhaust motorized valve is opened , 1# exhaust motorized valve is opened by means of interlock

Boiler reheated steam header starting 1# and 2# exhaust motorized valve, (1)

After 2# exhaust motorized valve is closed , 1# exhaust motorized valve is closed by means of interlock

(2)

After 2# exhaust motorized valve is opened , 1# exhaust motorized valve is opened by means of

Remarks



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interlock Open/close conditions on the continuous blow down motorized valve and continuous blowdown control valve (1)

After opening the continue blowdown motorized valve, the manual control is allowed to open the control valve

(2)

After closing the continuous blowdown control valve, the interlock –close is performed or the manual control is allowed to close the continuous blowdown motorized valve

1# and 2# emergency drain motorized valves for boiler (setting the interlock operation switch)

(1)

The 1# and 2# emergency drain motorized valve shall be closed by means of interlocking when the drum level falls to below 100MM; high water-level alarm should be performed.

(2)

The 1# and 2# emergency drain motorized valve shall be opened by means of interlocking when the drum level reaches 150MM; high water-level alarm should be performed.

Interlock conditions for desuperheating water motorized valve and control valve

(1)

When MFT motion or load is less than 20%, the main motorized valve and motorized sub-valve of overheating system desuperheating water shall be closed by means of interlocking, and all desuperheating water control valves shall be automatically transformed into manual operation and closed by means of interlocking.

(2)

When the first stage desuperheating water control valve for superheater is closed (<5%) or MFT motion or load is less than 20%, interlock-close the corresponding motorized sub-valve of the superheater desuperheating water.

(3)

When the first stage desuperheating water control valve of superheater is opened (>5%), interlock-open the corresponding motorized sub-valve of the superheater desuperheating water..

(4)

When the second stage desuperheating water control valve at A side of the superheater is closed(<5%) or MFT motion or load is less than 20%, close the corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(5)

When the second stage desuperheating water control valve at A side of the superheater is opened(>5%), open the corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(6)

When the second stage desuperheating water control valve at B side of the superheater is closed(<5%) or MFT motion or load is less than 20%, close the



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corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(7)

When the second stage desuperheating water control valve at B side of the superheater is opened(>5%), open the corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(8)

When the third stage desuperheating water control valve at A side of the superheater is closed(<5%) or MFT motion or load is less than 20%, close the corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(9)

When the third stage desuperheating water control valve at A side of superheater is opened(>5%), open the corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(10)

When the third stage desuperheating water control valve at B side of superheater is closed(<5%) or MFT motion or load is less than 20%, close the corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(11)

When the third stage desuperheating water control valve at B side of the superheater is opened(>5%), open the corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(12)

When each stage desuperheating water control valve of the superheater is closed (<5%), close the corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(13)

When each stage desuperheating water control valve of the superheater is opened((>5%), open the corresponding motorized sub-valve of the superheater desuperheating water by means of interlocking

(14)

When MFT motion or load is less than 20%, the main motorized valve and motorized sub-valve of reheating system desuperheating water shall be closed by means of interlocking, and each desuperheating water control valves shall be automatically transformed into manual operation and closed.

(15)

When the desuperheating water control valve at A side of the reheater is closed(<5%) or MFT motion or load is less than 20%, close the corresponding motorized sub-valve of the reheater desuperheating water by means of interlocking

(16)

When the desuperheating water control valve at B side of the reheater is opened(>5%), open the corresponding motorized sub-valve of the reheater desuperheating water by means of interlocking



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(17)

When the desuperheating water control valve at B side of the reheater is closed(<5%) or MFT motion or load is less than 20%, close the corresponding motorized sub-valve of the reheater desuperheating water by means of interlocking

(18)

When the desuperheating water control valve at B side of the reheater is opened(>5%), open the corresponding motorized sub-valve of the reheater desuperheating water by means of interlocking

(19)

When the emergency spraying control valve of the reheater is closed(<5%) or MFT motion or load is less than 20%, close the corresponding emergency spraying motorized sub-valve of the reheater by means of interlocking

(20)

When the emergency spraying control valve of the reheater is opened(>5%), open the corresponding emergency spraying motorized sub-valve of the reheater by means of interlocking

Main motorized valve of heating steam at the boiler (starting)bottom (1)

Starting is allowed when FBT (furnace bottom temperature) is less than 80℃ and MFT exists

(2)

Without MFT, close is made by means of interlock and starting is forbidden.

(3)

When drum pressure reaches 0.2Mpa, close by means of interlocking is performed and starting is forbidden.

Motorized valve of steam supply pipe from the cold section of boiler reheater to the auxiliary steam main pipe

11.2.5

(1)

Starting is allowed when the pressure of cold section of reheater is greater than that of the auxiliary steam main pipe

(2)

Close is made by means of interlock and starting is forbidden when the pressure of cold section of reheater is equal to or less than that of the auxiliary steam main pipe

(3)

Close is made by means of interlock and starting is forbidden when the load of unit is greater than 70%.

Interlock protection test on flue-gas temperature probe and pneumatic oscillating device of burner, including: No.

Test item

Flue-gas temperature probe A(DCS) (1)

Forward, reverse, suspend, reset(ensuring that the advancing and regressing travel is in place)

Fixed value

Results

Remarks



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(2)

Repeat(automatic)

(3)

Over-load trip, alarm

(4)

High temperature, alarm

(5)

High high temperature, quit automatically , alarm

Flue-gas temperature probe B(DCS)

11.2.6

(1)

Forward, reverse, suspend, reset(ensuring that the advancing and regressing travel is in place)

(2)

Repeat(automatic)

(3)

Over-load trip, alarm

(4)

High temperature, alarm

(5)

High high temperature, quit automatically , alarm

Interlocking protection test on pneumatic oscillating device of burner, including: No.

Fixed value

Test item

Pneumatic oscillating lower device group of

burner

(1)

DCS command is consistent with the one of site feedback(0%, 50%, 100% command)

(2)

Site openness is consistent with the actual position

(3)

Horizontal position deviation is less than 5%

(4)

Automatically adjusting position(50%) after MFT

to

the

horizontal

Pneumatic oscillating upper device group of burner (1)

DCS order is consistent with the one of site feedback(0%, 50%, 100% order)

(2)

On-site openness is consistent with actual position

(3)

Horizontal position deviation is less than 5%

Results

Remarks

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure (4)

11.2.7


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Automatically adjusting position(50%) after MFT

the

horizontal

Interlock protection tests on flame scanning fan, including: No.

11.2.8

to

Test item

(1)

Stop permissive conditions

1)

MFT action has delayed for 12h, or another flame scanning cooling fan is running, air pressure of flame scanning cooling fan is normal (5kPa-8kPa) and furnace temperature is less than 80℃

(2)

Interlock protection

1)

Flame scanning cooling fan is in standby state and the other flame scanning cooling fan is out of work

2)

The flame scanning cooling fan is in standby state and its low main pipe pressure signal is transmitted

(3)

Operation and standby conditions

1)

Any flame scanning cooling fan runs

Fixed value

Results

Remarks

Fixed value

Results

Remarks

Interlock protection test for intermittent bolwdown pit, including: No.

Test item

(1)

Draining pump A

1)

Interlock starting condition: (1) When the interlock button is pressed, the draining pump B in the intermittent bolwdown pit has tripped or has been operated. If the water level is high, it shall be delayed by 20S. (2) Button A is selected to press, the water level of intermittent bolwdown pit is high and two pumps have not operated uniformly.

2)

Conditions for interlock suspension : Water level of the intermittent bolwdown pit is low; Two pumps has operated uniformly, the water level of intermittent bolwdown pit is intermediate, the button A is selected and isn’t



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pressed. (2)

Draining pump B

1)

Conditions for interlock initiation including the followings: (3) When the interlock button is pressed, the draining pump B in the intermittent bolwdown pit has tripped or has been operated. If the water level is high, it shall be delayed by 20S. (4) Button A is selected to press, the water level of intermittent bolwdown pit is high and two pumps have not operated uniformly. Conditions for interlock suspension : Water level of the intermittent bolwdown pit is low; Two pumps have operated uniformly, the water level of intermittent bolwdown pit is intermediate, the button A is selected and is not pressed.

2)

11.2.9

Interlock protection test on flame CCTV, including: No.

Test item

(1)

Flame CCTV A

1)

Conditions for interlock quit :

Alarm on out of gas supply at flame CCTV A side

Alarm on over temperature at flame CCTV A side

(2)

Flame CCTV B

1)

Conditions for interlock quit: (following condition or):

Alarm on out of gas supply at flame CCTV B side

Alarm on over temperature at flame CCTV B side

Fixed value

Results

Remarks

Inspect and operate the following system according to the sequence (the specific operation refers to the operation manual on boiler) 11.3

Inspect and operate the cooling water and compressed air system (1)

The circulation water system and the corresponding interlock protection are put into



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operation;

11.4

(2)

The demineralization replenishment system and the corresponding interlock protection are put into operation;

(3)

The cooling water system of the steam turbine and the corresponding interlock protection are put into operation;

(4)

The cooling water system of the boiler and the corresponding interlock protection are put into operation;

(5)

The compressed air system and the corresponding interlock protection are put into operation;

Inspect and operate the high and low-pressure water supply system, feed the water to the boiler, blow and prepare the hydraulic test for boiler (1)

Inspect and confirm whether the system is provided with starting conditions, start the condensation system and feed the water to the deaerator;

(2)

Inspect and confirm whether the electric water supply pump and its system are ready for starting. (run the corresponding interlock protection), start a water supply pump;

(3)

Confirm that the boiler is ready for feeding and feed the water to the boiler;

(4)

Flush the waterside part of the desuperheating water system of superheater;

(5)

Inspect and confirm that the boiler proper and its system are provided with the water pressure condition;

(6)

After the boiler water feeding is up to the visible water level, confirm that it is provided with the water pressure condition.

11.5

Water pressure test for boiler

11.5.1

Scope for water pressure: rear of water supply console --- economizer---drum and water-cooling wall --- superheater— at the block plate of water pressure for the main steam pipeline (the water pressure block plate is required to be installed and removed after the water pressure test is completed.)

11.5.2

Control for water feeding speed (1)

Water feeding flow: 30－60 tons/h;

(2)

Water feeding duration: 2－4 hours;

(3)

Temperature for water feeding: 40―70ºC;

11.5.3

After water emits from the air vent fully, close the corresponding air valve.

11.5.4

After all the air valves are closed, pressure rising begins.

11.5.5

Pressure rising speed: (1) Drum pressure<0.98MPa；pressure rising speed <0.244MPa/min； (2) Drum pressure>9.80MPa；pressure rising speed <0.196 MPa/min ； (3) Drum pressure>17.00MPa；pressure rising speed <0.098 MPa/min 。

11.5.6

When the pressure rises up to the values below, the pressure rising should be maintained for inspecting and confirming whether there are leaking points and other abnormality. (1) Drum pressure：5.88MPa；



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(2) Drum pressure：11.77MPa； (3) Drum pressure：17.50MPa。 11.5.7

When the drum pressure rises up to 17.40MPa, inspect that the system is free of leakage and shut off the water supply and watering valves as well as lower the rotary speed of water supply pump to ensure that the outlet pressure of water supply pump is up to 15.00 MPa, meanwhile, 5 minute timing begins; if the reduction value for the drum pressure is less than 0.50MPa, water pressure test is qualified. Otherwise, the leakage for the system should be inspected.

11.5.8

After the water pressure test is completed, pressure reduction begins. The speed for pressure reduction is equal to or less than 0.50MPa/min.

11.5.9

In the process of depressurization, flush the system below: (1)

Sampling pipeline for superheated steam, saturated steam and boiler water

(2)

I&C pipeline for drum pressure and superheated steam pressure

11.5.10

Open the drain valve for the superheater and main steam pipeline as well as the discharge valve for water cooling wall to drain the water.

11.5.11

Dismantle the water pressure block plate of the main steam pipeline

11.5.12

Flush the cold state water of boiler. The watering and draining work of the boiler should be carried out for many times until the boiler water is adjacent to the water quality of demineralization water.

11.6

Ignition preparation

11.6.1

After receiving the ignition command, perform the preparation prior to ignition according to the operation regulation.

11.6.2

Prior to ignition, the operator should carry out the overall inspection for the equipment and system, the blow command group should organize the related personnel to perform the inspection and test for following items: (1)

Inspect that the clearance of expansion of each position is greater than the specified expansion value, all the expansion indicators should be in zero position and the record should be made properly.

(2)

Inspect whether the nozzles of each burner are in the horizontal location.

(3)

Inspect the fastening condition of each hanger; all kinds of hangers and suspenders should be secure.

(4)

Perform the programmed control test for the subsidiary blowing of air pre-heater.

(5)

Perform the operation test for each damper, baffle and motorized valve;

(6)

Perform interlock, protection and signal tests and inspect the protective setting value;

(7)

The operational test for inspection of the furnace flue-gas temperature probe and starting for the flame-scanning fan.

(8)

Operation test for the temporary control door

(9)

The appearance inspection for the temporary blowing pipeline; the supports and hangers should be secure and the density should be satisfied not to produce the vibration or displacement arising from the counter force of airflow.

(10) Confirm the water level for the drum is at +200MM; systems such as the sealing for the boiler bottom, deslagging, heating of electric precipitator, draining of boiler and air vent



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are put into service. Start the oil pump, the stokehole circulation is made for the fuel. (11) Ensure the compressed air system and water cooling system are put into service; (12) Start up the water feeding of boiler and ignition. Contact the shift supervisor to supply the steam to the auxiliary steam header. (13) Operate the heating system of furnace bottom, control the temperature rise ratio ≤28℃ ／h and control the upper and lower wall temperature difference of drum≯40℃. (14)

Notify the steam turbine to run the lubrication oil system and the jacking oil system as well as the barring device;

(15) Prior to ignition, start up the bypass valve of the temporary control valve and the drainage relevant with the blowing system to avoid water impact accidents. (16) Operate the sealing system for the boiler bottom and establish the sealing. (17) Inspect the lubrication oil station of the preheater and start the operation of the oil station (the oil pump is in the standby state and to be started); (18) Inspect the cooling fan system of the induced draft fan and run the cooling fan and the interlock. (19) Inspect the lubrication oil station of the forced draft fan and run the oil pump and the interlock. (20) Inspect the preheater, induced draft fan and forced draft fan and confirm that they are ready for starting. (21) Operate the flame scanning cooling air system and the interlock. (22) Inspect the SCS system to ensure that such interlock protection for the pre-heater, induced draft fan and the forced draft fan is in operation state. (23) Inspect the BMS system to ensure that the management system for boiler burning is in operation state. (24) Run flame and water level CCTV; (25) Inspect and confirm the fuel system and put into operation. (26) Inspect and confirm that the I&Cs are ready for use. (27) In accordance with the requirement for the start and operation manual of unit, confirm that each drain valve should be in the correct state prior to ignition. (28) Open the drainage at different levels for the main steam pipeline at the steam turbine side, the steam-reheating pipeline at the cold and heat section and high -low bypass system. (29) Properly isolate the system related to the blowing system to ensure the steam of blowpipe is not mixed into other systems. (30) Open the bypass valve of the motorized valve controlled temporarily for blowing. (31) After the target device is fitted via the cold state, confirm that it is reliable and available (32) Confirm that the removal for the water pressure block plate is completed and the system is restored normally.

12.

Temperature rising and pressure rising for boiler ignition

12.1

Confirm that the ignition condition is provided to get the approval of the general director for commissioning. According to the DCS procedure, employ the light diesel to ignite.



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(1)

Start the flame scanning cooling fan and implement interlock of standby fan.

(2)

Suspend the heating system at the bottom and ensure the drum level is at about -100mm.

(3)

Start two air preheaters and use interlock.

(4)

Start the induced draft fan and forced draft fan.

(5)

Establish the airflow for blowing, blowing the furnace for 5 minutes and resetting MFT.

(6)

Perform the leakage test for fuel system.

(7)

After the leakage test is qualified, blow it once more and reset MFT, adjust the total airflow and the openness of the secondary damper, the pressure difference for the secondary air of furnace is 250~450Pa, the negative pressure of furnace is about -50Pa.

(8)

Inspect the openness for all the baffles on the air duct and flue are in proper location.

(9)

Confirm that the boiler protection has been inputted fully. If the conditions are not met, the protection should be approved by the headquarter, I&C is cut off temporarily and the record should be made properly. When the protection conditions are met, timely notify I&C to put into protection.

(10) Establish and maintain the boiler fuel pressure within 3.1-3.3 MPa. According to the condition, ignite and start 1~ 2 oil guns; after ignition, take notice to inspect the ignition and atomizing condition and timely adjust the operation condition of oil gun to ensure the favorable atomizing and clear flame, free of black smoke. At the initial stage of ignitions, the oil gun at the lowest layer should be selected to start in opposite angle, the angles should be switched once as per 30 minutes ( such as: the first and the third angle are tangent towards the second and the fourth corner) to ensure the uniform heating of water cooling wall. When filling the oil, the condition for air distribution should be inspected and the proper adjustment should be made timely to ensure the full ignition; the oil gun with insufficient ignition should be dismantled to inspect and clean; after the ignition fails or the oil gun put out a fire, timely cut off the fuel; after the blowing for the oil gun and furnace ventilation is completed, the re-ignition can be made. (11) Notify the thermal technician to debug the oil fire check. After the oil fire is debugged normally, the flame check should be started immediately. (12) After the ignition is normal, the flue-gas temperature probe at the furnace outlet shall be used. When the steam fails to get through the reheater, the flue-gas temperature at the furnace outlet controlled shall not exceed 538℃ during pipe blowing. If the flue-gas temperature exceeds 538℃, fuel quantity should be reduced timely to ensure the safe operation of the reheater. (13) Other oil guns should be commissioned continuously, and the combustion adjusting work and the fire check commissioning work should be carried out. After the oil burner functions normally, the standby one will be out of service immediately. (14) The auxiliary steam blowing for the air preheater should be started uninterruptedly. (15) Based on the temperature rising and pressure rising speed, it is required to increase the oil gun additionally. The temperature rising and pressure rising speed shall be controlled in compliance with the temperature/pressure rising ratios for boiler water saturation, referring to the table below:

Main steam pressure MPa

＜0.98

0.98--3.92

3.92--9.8

9.8--18.2

Temperature rising ratio℃/h

＜28

＜56

≤30

≤36



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Pressure rising ratio MPa/min

---

≤0.03

≤0.05

≤0.06

(16) When the boiler starts up for the first time, it is noticed specially to monitor the expansion conditions in each position. The dedicated person is required to record the expansion for installing and operation. The expansion time is recorded: prior to boiler water feeding and after feeding; the drum pressure at the stage of ignition and pressure rising refers to 0.49 MPa, 1.47 MPa, 2.45 MPa, 3.43 MPa, 4.20 MPa, 5.86 MPa and 6.50 MPa. If the expansion is affected or the expansion is abnormal, the report should be conducted to suspend the pressure rising, after the abnormity is eliminated by taking the measures via negotiation, the pressure rising can be performed continuously. (17) The temperature difference for the upper and lower wall of drum should be controlled up to be less than 40℃. (18) When temperature is rising and the pressure is rising, open the related drain valve as well as monitor and maintain the pipe wall for the super heater and reheater not overheating. (19) When the drum pressure rises to 0.2MPa, shut the drums and the air valve for the super heater at different levels and shut all atmospheric relief valves. (20) When the drum pressure rises to 0.3-0.5MPa, flush the local water level gauge of drum. The Contractor flushes the instrument tube, sampling pipe and hot spring bolts. (21) In the process of temperature and pressure rising as well as pipe blowing, the quality of boiler water should be controlled. Based on the analysis for the chemical water quality of the boiler, the sewage discharge shall be performed to improve the boiler water quality. Therein, the sewage discharge should be performed regularly and the program control should be used as possible. (22) When the drum pressure rises to 0.5-1.0MPa, close the drain valve beside the boiler as well as arrange the chemical dosing system and continuous drainage work regularly, strengthening the drainage of grain collector. (23) When the drum pressure rises to 1.0MPa, open the bypass valve of control valve to warm the pipe. When warming the pipe, the expansion condition for the pipeline and the stress condition for the supports and hangers should be inspected, especially for inspecting the strictness of block plate for the high and medium pressure main steam valve as well as the expansion and stress condition of temporary system. If the problems are found, timely report it and take the measures to cope with it. (24) When the drum pressure rises to 3.0MPa, the temperature of super heating steam is greater than 350℃ and the exhaust temperature of the temporary pipe is greater than 180℃, the trail blowing work for the first time can be carried out. (25) After steam is generated from boiler and steam pressure is established, strengthen the monitoring for the cylinder temperature of steam turbine. Monitor the turbine-turning device to ensure the continuous operation. 13.

Blowing procedure

13.1

Trail blowing Prior to the formal blowing, four trail blowing tests with drum pressure of 3.0MPa, 3.5MPa, 4.0MPa and 4.5MPa shall be performed to inspect the safety and operation of the whole blowing system. The operators and the operators for the control valve should seek for the operation skill and master the control method for water level to ensure the accurate display for the water supply flow.



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When performing the trail blowing every time, sufficiently warm the pipe and strictly inspect the expansion and stress conditions, after the expansion and stress conditions for the system (including the temporary system) are confirmed to be normal, the formal blowing can be performed. During the trail blowing, if the problems are found, timely report and eliminate them. If the major problems are found, timely report them, shut off the temporary control valve and break off the power supply as well as stop blowing; after the measures are taken to demolish the hidden troubles, perform the trail blowing again.

13.2

(1)

When the drum pressure rises to 3.0MPa, the first –time trail blowing shall be performed. Open the control valve of blowing and close it after full open.

(2)

Inspect whether the heat expansion and the stress of bracket are normal for the blowing pipeline system, after the normality is confirmed, the pressure rising is made again to prepare the purge next time. Otherwise, the pressure rising is suspended to treat the problems on heat expansion and stress of bracket.

(3)

When the drum pressure rises to 3.5MPa, the second trail blowing shall be performed. When performing the second trial blow, add a piece of target on the target device to show the original state of pipeline system.

(4)

Inspect whether the heat expansion and the stress of bracket are normal for the pipeline system of blowpipe, after the normality is confirmed, the pressure rising is made again to prepare the purge next time. Otherwise, the pressure rising is suspended to treat the problems on heat expansion and stress of bracket.

(5)

When the drum pressure rises to 4.0MPa, the third trial purge shall be carried out.

(6)

Inspect whether the heat expansion and the stress of bracket are normal for the blowing pipeline system, after the normality is confirmed, the pressure rising is made again to prepare the purge next time. Otherwise, the pressure rising is suspended to treat the problems on heat expansion and stress of bracket.

(7)

When the drum pressure rises to 4.5 MPa, the fourth trial blow shall be carried out. Inspect whether the heat expansion and the stress of bracket are normal for the blowing pipeline system, after the normality is confirmed, the pressure rising is made again to prepare the purge next time. Otherwise, the pressure rising is suspended to treat the problems on heat expansion and stress of bracket.

(8)

When the drum pressure rises to 5.5 MPa, the formal blow shall be carried out.

The formal blow at the first stage Formal blow: the pressure to open the temporary valve is around 5.5~6.5MPa, when the drum pressure is about 3.8~4.2MPa, shut off the temporary valve. The pressure control after the valve closing for blowing every time should be based on the principle that the saturated temperature of drum is not greater than 42℃. When blowing, start up the pressure of temporary control valve and the pressure of valve closing, the blowing parameters shall be selected according to table 9.1. (1)

The blowing process for pressure reduction belongs to the working condition that the parameters vary violently, the water charging operation for the boiler should be paid attention specially. Prior to opening the control valve, the water level shall be controlled around -50-- -100mm, under the premise of reliable water supply, open the temporary control valve. After the temporary control valves are opened fully, the water charging capacity should be increased gradually; prior to closing the temporary control valve, water charging capacity should be increased, after the temporary control valves are closed fully, the water level shall be changed from the false water level to the true water level, until the water level drops continuously no longer and begins to rise, the water charging capacity can be reduced to ensure that the water charging reaches the normal water level. The water charging temperature should be raised as possible; in addition, the preparation for the water capacity should be sufficient.


13.3


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(2)

In the process of blowing, the date acquisition should be conducted according to the record form prepared previously. It is noticeable that the data acquisition should be complete.

(3)

In the process of blowing, a set of pulverizing system of E or D shall be used according to the combustion condition. After the pulverizing system is put into operation, the metal temperature of the pipe wall for the super heater or reheater should be monitored strictly not overheating. After pulverizing, the outlet temperature of superheater or the reheater should be confirmed whether to be controlled effectively below 450℃. It is prohibited to operate at over temperature.

(4)

The blowing coefficients shall be calculated according to the differential pressure method to adjust the blowing pressure up to the appropriate value.

(5)

After around 20- time blowing is performed, two-time target practice on target shall be conducted; the blowing -down time more than 12 hours should be arranged according to the situation.

(6)

Prior to shutdown cooling, blow the following systems: Blowing pipes for each stage desuperheating water of superheater as well as the steam -side pipeline for the emergency spraying system of reheater. About 5-time blowing with duration of 3~5 minutes every time should be performed for each pipeline.

(7)

At least 12 hours are required for shutdown cooling. After flameout, great airflow is required to blow the furnace for 5 minutes, sealing the furnace.

(8)

During cooling, the following operation should be performed: 1)

Heat standby of boiler. Maintain the normal water level; monitor and record the flue-gas temperature at the back-end; prevent the combustion accidents at the back-end and carry out the accident anticipation.

2)

Arrange the workers to clear the grain collector;

3)

Clear the strainer of the electric water supply pump;

4)

Eliminate the defects found at this stage;

5)

Resume the desuperheating water pipeline system at different stages for the superheater (after the pulverization is used at the first stage of blowing, if the steam temperature exceeds 450℃, it shall be out of control.)

6)

Resume the pipeline of emergency spray water system for the superheater (after the pulverization is used at the first stage of blowing, if the steam temperature exceeds 450℃, it shall be out of control.)

7)

Installing and commissioning the control valve and flow device for the desuperheating water system. (note: the necessary measures should be taken to prevent the foreign matters remaining inside the pipeline during installation.).

Formal blowing at the second stage (1)

After the system is cooled for 12 hours, the reigniting, pressure rising and pipe warming for the boiler shall be performed.

(2)

The trail blow for the drum pressure at 3.0～5.0MPa shall be carried out to ensure that the system is heated sufficiently to inspect the expansion and stress conditions.

(3)

If there is free of abnormity, continuously raise the pressure up to 5.5~6.5 MPa to perform the formal blowing.

(4)

Based on the requirement of temperature rising and pressure rising, after the condition of coal feeding is met, the E or D pulverization system should be put into operation. The



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combustion adjustment should be performed and I&C should be performed dynamic commissioning and operation for coal flame scanning. (5)

During blowing at this stage, alternatively perform the blowing of high and low pressure bypass pipeline blowing as well as the service steam system blowing for the steam system. 4~ 5-time blowing is performed respectively. The manual clearing is performed for the low-pressure bypass pipeline.

(6)

Repeatedly perform the formal blowing, until the target is qualified.

(7)

Acceptance and appraisal for blowing quality: at the later stage of blowing, inspect the target installing and blowing condition, continuously inspect the target installing; after two-time continuous inspection is qualified via the supervisor, when blowing is completed, and quality acceptance and assessment shall be conducted.

(8)

Prior to completion of blowing, strengthen the blowing work at the back end.

(9)

After blowing is completed, the great airflow is required to blow the furnace for 5 minutes after the boiler flameout, the furnace should be sealed. The boiler cools naturally. When the drum pressure reaches 0.8MPa, the boiler draining shall be carried out. The draining with pressure and residual drying shall be taken to perform the dry protection.

(10) The steam turbine should keep the turning device operating until the cylinder temperature of steam turbine reaches the shutdown condition for the turning device to shutdown the turning device. (11) When the boiler is not cooled up to the normal temperature, the normal water level should be remained. When operating, the flue-gas temperature of back-end is required to be monitored and recorded; preventing the combustion accident at the back-end and the accident anticipation should be performed properly. (12) When the drum pressure drops to the normal temperature, the restoration for the temporary pipeline system can executed via approval. 13.4

During blowing at the second stage, the coal burner and the coal pulverizing system are put into service (1)

Start ventilation and blow the furnace, resetting MFT.

(2)

Start the primary air fan and seal the fan.

(3)

Confirm the opening for the drain valve of superheater or the reheater, the draining of the main steam pipeline at the steam turbine side and the bypass draining of temporary control valve.

(4)

Inspection prior to starting the fuel oil system and oil gun

(5)

Operate the flue-gas temperature probe of furnace; start the fire scanning cooling fan, interlock; confirm that the primary and the secondary valves are closed for the lower heater of the water cooling wall; inspect that the openness for all the baffles on the air duct and flue duct should be located in the correct location and confirm that the deslagging system functions normally .

(6)

Confirm that the condition of the coal filling layers is satisfied; ensure that the number of the oil gun for the furnace is up to over 8 pieces, in addition, the temperature of hot air should be greater than 150℃, and then the coal pulverizing begins.

(7)

Take the operation for the E coal pulverizing system as the sample: open the blanking valve supplying the coal powder for E –layer burner.

(8)

Adjust the primary airflow of the coal mill up to 50t/h and warm up the mill E for 15 min..

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure (9)


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Confirm the oil guns in the AB layer are burned, the combustion should be stable; when outlet temperature of mill E is up to 65℃--82℃, start up the coal feeder E, and timely increase the coal quantity of coal feeder E up to the lowest coal supply capacity of 8--10t/h ( the coal feeding ratio is 20%--25% rated output of coal mill), under the low load ratio, if the coal mill is found vibration, the coal feeding capacity should be increased, generally, after the coal bed is formed between the mill bowl and mill roller, the vibration can disappear.

(10) The iginition of the burner should be confirmed to be normal. If the coal powder can not be burned timely, immediately suspend the coal feeder. After the causes are analyzed, it can be put into service. (11) After each burner burns for 10 mins stably, adjust the coal capacity of coal feeder appropriately based on the curve of temperature rising and pressure rising. The normal operating parameters for the coal mill should be monitored and maintained to avoid the vibration and the abnormality of the bearing temperature. After the favorable combustion is ensured, I&C should be performed hot commissioning for coal flame scanning. After the fire scanning commissioning is normal, startup should be performed timely. (12) After the coal powder is put into service, the steam temperature and the steam pressure can rise greatly. The oil filling capacity should be reduced appropriately to control the combustion ratio. When the steam does not get through the reheater, during blowing, the flue-gas temperature at the outlet should be controlled not to exceed 538℃, if the flue-gas temperature exceeds 538℃, fuel feeding should be lowered to ensure the safety operation of reheater. During blowing, the steam pressure and the temperature for the super heatershould be controlled to below 7.0 MPa and 450℃ respectively. Otherwise, the combustion is required to be weakened 13.5

Complete trial run record The main parameters in the commissioning of boiler blowing should be listed in the Record List for Parameters of Boiler Blowing, referring to Appendix 3.

14.

Safety Measures

14.1

Safety rules for commissioning

14.1.1

The parties participating in commissioning shall be familiar with and abide by the relevant safety rules on site, and wear reasonable clothing and appropriate personal protective equipments.

14.1.2

In case of any accident that damages the equipment or hurts person happened or possibly happen during commissioning, suspend commissioning immediately and put the equipment to the lowest energy state. Investigate the cause and take corrective measures.

14.1.3

The parties participating in the commissioning will obey the command of commissioning personnel. In case there is an emergency endangering personal or equipment safety, any person has the right to stop the operating equipment immediately and report to the control room.

14.1.4

In the entire process of blowing, all the professionals should be in post to ensure the safety for the equipment operating.

14.2


Rotating the equipment Injuries might be caused by rotating equipment during commissioning or test. Therefore, special care must be taken during work and do not touch the rotating components with tools or your hand。



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Failing to wear or misuse the safety helmet When adjusting or testing, injuries and deaths might be caused by the striking of the objects. When entering the production site, properly wear the safety helmet and tightly tie the cap belt. The dangers above the operation region and the falling objects aloft in the periphery should be inspected.

The damage and burn arising from blowing temporary pipeline All the temporary pipelines are required to perform the heat insulation. Prior to blowing, the pipeline should be warmed sufficiently to avoid the water attack accident, and at 40%—50% and 70%—80% of blowing pressure , trail blowing shall be performed in several times. Steam scalding and noise pollution at the exhaust of blowing The safety isolation measures should be taken strictly at the exhaust of blowing, the dedicated person should be designated.

The mis-operation for the temporary control valve shall lead to the damage of equipment and the personnel injury. Hang the operation prohibiting plate; strictly execute the power failure rule when replacing the target. For each blowing, the installation contractor must execute it after the personnel withdrawal. Strictly follow operation procedures, adhere to operation approval system and never carry out work not approved。

The high- temperature flue gas emitted from the observation hole and manhole door can hurt the person. All the manhole doors and observation holes are sealed and closed respectively. Prior to observing the fire on site, appropriately raise the pressure of furnace. When observing the fire, stand on the side of observation hole and prepare to evacuate at any time.

14.3


Abnormal running of equipment If it is found that operating equipment makes abnormal sound or has other abnormal condition, and such problem may not be eliminated, stop such equipment and report to the control rooms immediately.

Accidental fire and fire hazard of fuel oil system When commissioning, prepare the strict firefighting measures; the inflammable and explosive objects should be far way from the periphery of blowing pipeline; the sufficient firefighting appliances must be provided on site

Ignition of the platform for the coal mill The dedicated person should be assigned to monitor it. The temporary firefighting devices are placed herein, and the firefighting system of the coal pulverizing system should be in standby state.

Ignition and combustion due to over temperature inside the coal mill The operator should elaborately perform the operation and maintenance and strictly control the outlet temperature of mill; the routing inspection should be strengthened, the report should be submitted when finding the problems; several temporary firefighting devices should be placed, in addition, the firefighting steam system of coal pulverizing system should be in standby state.



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Iginition of the platform for the burner The dedicated person shall be assigned and the temporary firefighting devices shall be placed herein, the telephone or the walkie talkie should be employed to contact with the central control room.

Deflagration at the time of extinguishing due to unstable combustion The extinguishing protection must be used, the coal powder fineness should be controlled reasonably, and the operation and maintenance should be performed elaborately, if the combustion is instable, timely start the oil gun, properly prepare the accident anticipation.

Over temperature and over pressure can damage the equipments and hurt the person. The fuel should be used slowly and stably, the supervising for the wall temperature and the temperature at the place of flue-gas temperature probe should be strengthened. If the combustion ratio is out of control, timely shut down the boiler and prepare the pressure releasing accident anticipation. The outlet pressure of the superheater should be controlled to be not greater than 7.0 MPa, the temperature for the superheater or the reheater should not be greater than 450℃.otherwise, the combustion must be weakened and the pressure releasing must be performed.

The combustion of pulverized coal deposits at the back-end damaging the equipment The regular analysis should be performed and the coal fineness should be remained within the specified scope. The combustion adjustment should be strengthened to ensure the favorable combustion. The air pre-heater should be started continuously to perform the soot blowing. After shutdown, the normal water level must be remained; the closed system must be purged with the great air flow, meanwhile, the monitoring for the flue-gas temperature at the back-end should be strengthened, if the problem is found, timely treat it; irregularly inspect the accumulated dust at the convection flue gas pass; prior to starting the boiler once more, the great air flow should be employed to purge the boiler. The dedicated person should be assigned to monitor, the temporary firefighting device and firefighting system placed herein should be in standby state.

Serious water scarcity or overfeeding accident The proper control of drum water level is essential for blowing. Water supply of drum should be controlled properly; the water supply should be stable to avoid the overload for the pump, meanwhile, the false water level and true water level for the blowing should be distinguished to ensure not producing the serious water scarcity or overfeeding accidents. Requirement for water level control: after the control valve is opened, the steam pressure drops rapidly, meanwhile, the drum level also rises sharply, even overfeed, which is the false water level, now, the water supply should not be reduced, and on the contrary, with opening of blowing valve, the water supply capacity should be increased gradually. When the temporary control valve on blowing is closed, the drum level also drops, even the water level is invisible, therefore, when beginning to close the control valve, the water supply capacity should be increased, the water level for full closing of control valve should be remained in the visible water level as possible. When the water level begins to rise again, the water supply should be reduced immediately to avoid the over high water level. In order to avoid the serious water carrying of steam, prior to blowing the open valve, the drum level should be controlled around -100mm.

Preventing the water attack accident When blowing the pipe, the pipe warming should be warmed up sufficiently to avoid the water attack accident. Prior to blowing, the drain valve on the main steam pipeline should be opened completely; in addition, the warm pipeline behind the drain valve



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should be confirmed locally, the temperature is up to over 180℃; when performing the formal blowpipe, the drain valve on the main steam pipeline should be closed up to 1/3 of the full openness. During blowing the pipe, the openness condition for the bypass valve of the temporary control valve should be known specially. When the interval of blowing is too long (more than 2 hours), the bypassvalve should be opened fully, if necessary, a part of the temporary control valve should also be opened to ensure that the pipe warming is sufficient prior to blowing for the whole pipeline system. Water inflow and steam admission of gas cylinder During blowing the pipe, in order to prevent that the water and steam from entering into the gas cylinder, the temporary blowing system should be connected according to this measure strictly, and the isolation measures should be taken properly, meanwhile, the monitoring on cylinder temperature should be strengthened, the turning device system should be put into service. 14.4

Points for Attention of Safety

The uniform commissioning organization and the command should be established for blowing work of boiler. The sufficient personnel on operation, maintenance and safeguard should be provided. The production operators should be trained. The agents and the production operators should be familiar with the relevant equipment system, aware of the commissioning measures and understand their work scope and responsibilities as well as be familiar with the operation methods to prevent misoperation.

All the staffs to participate in blowing should observe the relevant safety stipulation on site. The flaw detection for all the steam and water system as well as the main reheating steam pipeline should be qualified to ensure that the blow work is carried out safely and reliably.

For the first ignition, the installation and manufacturing contractors should assign the dedicated person to inspect the expansion condition on boiler and steam pipeline system and record it properly. The fixing plugs fastened onto the pipeline supports and hangers should be confirmed to be removed already to ensure the normal expansion of the boiler and the entire blowing system.

When endangering the safety for the personnel and equipment in the process of blowing of boiler, the blowing work should be suspended immediately, if necessary, the operation of unit should be suspended, analyzing the causes and put forwarding the solution measures. After the accidents are removed, the blowing work shall be performed according to the decision of the headquarters.

During operating, the touring and inspection regulation on equipment system should be executed, during touring, if the problems are found; the report should be submitted to the commissioning and command department.

In the process of blowing, the warning line should be provided within the scope of commissioning equipment. The inflammable and explosive objects should not be provided in the periphery of pipeline for blowing. Persons are strictly forbidden in the periphery of 20m for the exhaust, the safety marks and warning line should be provided in the periphery, the dedicated person on safety should be assigned to safeguard.

The utility system should be isolated with the unit in construction and the operation prohibiting marks should be established. After the accident anticipation and the corresponding measures are taken properly, the blowing work can be developed. The blowing cannot affect the normal work of the unit installing.

Whether the muffler is installed at the exhaust should be decided and prepared by the Contractor; if the muffler is required to be installed, the muffler should be fastened on the cement pier on the zero -meter ground, the manufacturer of the muffler must have



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the certification on fabrication of pressure-bearing parts to guarantee the safety of blowing. The steam discharge capacity for the muffler should be 720 tons/h. the main parameters of muffler covers: Di≥670mm in inet dimension (being equal to or more than cross section of discharge pipeline), 300～400℃ in work temperature and being equal to or less than 1KPa for the pressure reduction that the steam gets through the muffler as well as being less than 80 DB out of 5m for the noise reduction capacity.

If the muffler is not installed at the exhaust, the huge noises produced by blowing can affect the living of the residents in the periphery. Considering the environmental protection, the headquarters should implement the conciliation work properly and decide the period of blowing. The time arrangemement should conform to the environmental protection requirement.

During blowing the pipe for the boiler, the firefighting system is in standby state and it can be used at any time.

When the ignition and pressure rising are carried out for the boiler, the dedicated person should be assigned to monitor the cylinder temperature of steam turbine, the dedicated person should be assigned to inspect whether the temporary facilities of high and medium combined steam valve are found leakage. In case of abnormal conditions, suspend blowing immediately. During blowing, the dedicated person should be assigned to inspect whether cylinder temperature rises for avoiding main shaft bending accidents arising from plenty of steam seeping into the steam turbine.

The proper control of drum water level is essential for blowing. Water supply of drum should be controlled properly; the water supply should be stable to avoid the overload for the pump, meanwhile, the false water level and true water level for the blowing should be distinguished to ensure not producing the serious water scarcity or overfeeding accidents

When replacing the target or clearing the grain collector, the contact should be strengthened, the steam -free state and outage of temporary control valve state should be confirmed to replace the targets and clear the grain collector, after replacing, the principal on blowing should be notified, and it is strictly forbidden that the control valve is opened in error to produce the accident.

Prior to opening the control valve for blowing, withdrawal of the person to replace the targets should be confirmed, there are free of constructors on the pipeline for blowing and the permission is obtained from the construction principal.

Due to the large pressure difference of temporary rush valve and frequent operation, the dedicated person should be assigned to maintain and ensure the fluent operation of blowing.

When blowing the pipe, the pipe warming should be performed sufficiently to avoid the water attack accident.

In the process of pipe blowing and pressure rising, the speed should be controlled to avoid the over temperature and over pressure, the temperature difference between the upper and lower wall of drum should be controlled strictly to be not greater than 40℃.

When the pressure rising and energy storage for the boiler are performed prior to opening the temporary control valve, the preheater is in parch state basically, the flue-gas temperature at the outlet of furnace should be strictly controlled to be below 538℃.

Prior to starting, the heating surface of air preheater should be confirmed to be clean, free of sundries. The soot blowing work of air preheater is performed continuously in the process of starting and blowing.

In the process of blowing, the condition on oil gun and coal powder combustion should



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be supervised to avoid oil leakage and entering into the furnace; the unchangeable combustion should be remained to keep the stable and favorable combustion, the flame inside the boiler should be distinct, the fluctuation on negative pressure of furnace is slight; and the furnace is bright and free of black smoke, meanwhile, the variation for steam temperature, steam pressure, wall temperature and flue-gas temperature should be supervised strictly to avoid producing the over temperature accident and the ignition accident of air preheater as well as the reburning accident at back-end.

15.

In the initial stage of coal feeding, the inspection and maintenance for ash and cinder handling system should be strengthened.

After the operation of coal pulverizing system is stable, the regular analysis should be implemented and fineness of coal powder should be remained within the scope specified.

In the entire process of blowing, the Contractor should strengthen the supervising on expansion and stress condition of temporary system, especially for the trail blowing stage.

Due to large water consumption in the process of blowing, the supervision on water level of deaerator and drum should be strengthened, and the continuous chemical water preparation should be kept to guarantee the fluent operation of blowing work.

When the heat standby or emergency shutdown of boiler is performed after the boiler is out of service, the normal drum level should be remained. As long as the boiler isn’t cooled below the normal temperature, the operators should supervise the variation of flue-gas temperature at the back-end, when there is the abnormal change, the preventive measures should be taken to organize and implement it pertaining to the specific problems and the data record should be made properly for future reference.

After blowing is completed and before the pipeline is restored, the construction conditions must be ensured to be satisfied: after the work sheets on construction permission are handled properly, the construction can be restored. After blowing is completed and when the system is stored, the Contractor must take the reliable measures, strictly prohibiting producing the secondary pollution.

During boiler steam blowing, the record on blowing parameters should be made properly. After blowing is qualified, the certification procedure should be handled.

Appendix


Appendix 1 No. 1


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Blowng condition checklist Items

Requirements

Result

Maintenance conditions

(1)

(2)

(3)

(4)

Temporary piping system for blowing

Flue-gas and air system

Flame system

scanning

Electrostatic precipitator system

Completion of temporary pipe and heat insulation (including drain, heat insulation, etc.)

□Yes □No

Completion for installation and commissioning of temporary motorized valve, bypass valve and drain valve.

□Yes □No

Completion for manufacturing and installation of target device and the quantity is sufficient.

□Yes □No

Qualified for on/off test and light signal of temporary motorized valve.

□Yes □No

Completion for installation and acceptance of temporary piping, fixing and sliding hanger for counter-force framework

□Yes □No

Completion of manufacturing and correct installation for the grain collector

□Yes □No

Completion for installation and calibration of the pressure gauge and the thermometer installed additionally for temporary system for blowing.

□Yes □No

Air pressure test is completed with acceptable quality

□Yes □No

Completion for installation and heat insulation of boiler proper and flue-gas and air duct

□Yes □No

Single commissioning for each fan and commissioning of subsystem

□Yes □No

Completion for inspection and adjustment of various air dampers and baffle with acceptable quality

□Yes □No

Completion for single commissioning and interlock protection test on flame scanning cooling fan with acceptable quality

□Yes □No

Completion for commissioning of CCTV system ,putting into service at any time

□Yes □No

Qualified commissioning for the flue-gas temperature probe of boiler

□Yes □No

Completion for installation of electrostatic precipitator and heat insulation with acceptable quality

□Yes □No

Verified by

Rema rks

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure No.

(5)

Items

Fuel oil system


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Requirements

Result

Qualified for air-flow distribution test, pressure rising and rapping test on electrostatic precipitator

□Yes □No

Completion for ash bucket heating device of the electrostatic precipitator and inspection with acceptable quality

□Yes □No

Completion for single trial use and installation of oil storage and stokehold fuel oil system as well as heat insulation work

□Yes □No

Completion for hydrotest of the stokehold fuel oil system and qualification for water and steam flushing

□Yes □No

Completion for installation of steam blowpipe of fuel oil system and adjustment on blowing valve

□Yes □No

Completion for motorized valve and pneumatic valve adjustment of fuel oil system with acceptable quality

□Yes □No

Qualification for the simulation test in related interlock protection(MFT AND OFT) of the fuel oil system

(6)

Boiler proper

Completion of the advancing and regressing test for oil gun and high-energy igniter

□Yes □No

Completion for each flame check static commissioning

□Yes □No

Installation of boiler proper and heat insulation are completed with acceptable quality

□Yes □No

Hydrotest of the boiler is completed with qualified acceptance.

□Yes □No

Water drainage, bleeding, regular draining, continuous draining, bottom heating, installation of nitrogenization system and heat insulation are completed fully. All motorized valve commissioning has been completed with acceptable quality

□Yes □No

The installation for the hydraulic block plate of the main steam pipeline at the superheater outlet has been completed and shall be removed after hydrotest.

□Yes □No

After hydrotest , all the hydraulic valve cores of the each safety valve for drum and superheater are removed, restoring formally and complying with the requirement of manufacturer. The hydraulic block plate shall be dismantled.

□Yes □No

Verified by

Rema rks


(7)

Items

Ash and cinder handling system


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Requirements

Result

The spring supports and hangers for steam-water pipeline are complete and the pin is removed, with free stress

□Yes □No

Motorized and pneumatic valve for each steam-water pipeline are adjusted to be qualified

□Yes □No

The expansion system of boiler proper is inspected jointly by each party to be normal and the expansion indicator is complete and adjusted to zero.

□Yes □No

Staircase, platform and rail of the boiler are complete with sufficient lighting and free of sundries.

□Yes □No

After pickling of boiler is completed, the inner arrangement for the steam drum should be cleaned to normal, the drum is closed and the temporary facilities should be removed, the formal system has been restored.

□Yes □No

The steam drum water-level gauge has been installed properly, and the SRTV has been adjusted and can be put into application

□Yes □No

Boiler water sampling and dosing system have been installed with acceptable quality ,providing with the operation condition

□Yes □No

Such systems such as feed water, desuperheating water, and emergency water spray have been installed completely. With qualified blowing, commissioning on motorized and pneumatic valve have been completed. The installation and heat insulation of temporary back-flush pipes at steam side of superheater (reheater) desuperheater are completed with acceptable quality.

□Yes □No

All the manhole doors and inspection holes in the boiler proper are complete and closed.

□Yes □No

The inspection for burner installation and coal flame checking commissioning under cold state are qualified, with normal operation conditions.

□Yes □No

Installation for slag pit (including the furnace bottom sealing), slag tank and rotating equipment are completed with acceptable quality.

□Yes □No

After trial use of each single equipment, on/off test on hydraulic shutoff valve is

□Yes □No

Verified by

Rema rks


Items


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Requirements

Result

qualified and can be put into operation.

(8)

(9)

Coal system

handling

Soot blower system

Coal pulverizing (10) system

(11) Air heater system

(12) Compressed air

The installation and commissioning work for the dedusting system equipment are completed, the logical commissioning for dedusting program control are completed, providing with operation conditions.

□Yes □No

Installation and trial use of each single equipment are completed with acceptable quality.

□Yes □No

The interlock protection test is qualified.

□Yes □No

Defects found in system commissioning have been eliminated, providing with coal feeding conditions.

□Yes □No

Completion of pipe installation and heat insulation

□Yes □No

Completion of installation and commissioning of motorized and pneumatic valve

□Yes □No

It can be put into operation at any time after completion of soot blowing test of air preheater.

□Yes □No

Completion of installation and heat insulation

□Yes □No

Qualified for commissioning of sealing fan

□Yes □No

Primary air leveling is qualified

□Yes □No

Calibration of the air volumn at the inlet of coal mill is qualified

□Yes □No

Completion of coal mill lubricating oil system commissioning

□Yes □No

Completion of cold state commissioning for the coal mill

□Yes □No

Completion of trial use of coal mill and coal feeder, providing with the commissioning condition;

□Yes □No

Completion of the transmission test for baffle system and damper

□Yes □No

Calibration for coal feeder weighing device is qualified.

□Yes □No

Completion of installation and heat insulation

□Yes □No

Completion of trial use of single equipment.

□Yes □No


□Yes □No

Completion of trial use for the single and

□Yes □No

Verified by

Rema rks


Items


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Requirements

Result

subsystem of instrument and service air compressor;

system

(13)

Fire protection water system

Industrial water (14) system

(15)

Auxiliary steam system

(16) Isolation

Chemistry water (17) system

(18) Steam Turbine

Completion of installation for instrument and service air gasholder as well as checkout of safety valve;

□Yes □No

Qualified for instrument and service air lines blowing

□Yes □No


□Yes □No

Completion of installation

□Yes □No

All fire-fighting equipments are complete, and watering test for firefighting water is qualified, being in reservation state.

□Yes □No

Fire-fighting equipments are complete in control room, electronic room and fuel oil system

□Yes □No

Completed installation and qualified hydraulic pressure

□Yes □No

It can be put into operation after completion of trial use.

□Yes □No

It can be put into operation after the completion for installation commissioning of boiler

□Yes □No

Completion of installation and heat insulation for auxiliary steam system

□Yes □No

The motorized valve of auxiliary steam system is qualified and can be put into operation.

□Yes □No

Completion of isolation of public with 2# unit

□Yes □No

It is provided with the feature of continuous chemical water supply

□Yes □No

Completion of commissioning for water charging system

□Yes □No

Condenser and hot well is qualified after cleaning; it is qualified for the condensing pump via commissioning, the blowing of system is qualified and can supply the water for deaerator.

□Yes □No

Inner of deaerator has been cleaned. After blowing, steam-heated pipelines are returned to normal and can be heated and applied.

□Yes □No

The electrically driven feed pump is qualified after commissioning. After blowing, the water supply pipeline is

□Yes □No

Verified by

Rema rks


Items


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Requirements

Result

returned to normal and can be put into operation.

2

Measures to prevent air from entering the turbine has been implemented and is qualified after inspection.

□Yes □No

Commissioning for steam turbine vacuum system is completed and can be put into operation;

□Yes □No

Commissioning for lubrication oil system of steam turbine, sealing oil system, and jacking oil system are completed. Turning device system is normal and can be put into operation.

□Yes □No

The main steam pipeline of steam turbine, reheating and recooling pipeline of cold and hot section as well as the high and low pressure bypass draining valve are confirmed to be qualified and can be put into operation.

□Yes □No

The commissioning for temperature measuring point of steam turbine cyliner has been checked and can show accurate temperature of the cylinder..

□Yes □No

All steam bleeding electric intercept valves are tested and qualified, with strict closeness.

□Yes □No

Drain introduced into the condenser has been reliably isolated.

□Yes □No

Low voltage turbine water spray can be put into operation.

□Yes □No

Electrical and Thermal Regulating conditions

(1)

Boiler FSSS(including fuel oil and coal filling part )

Completion of interlock test on flame scanning cooling fanl

□Yes □No

Completion of inspection on furnace blowing condition

□Yes □No

Completion of MFT test and interlocking test after MFT

□Yes □No

OFT test and completion of interlocking test after OFT

□Yes □No

Completion of fuel oil leakage test

□Yes □No

Completion of oil gun fueling management test

□Yes □No

Completion of coal feeder and coal mill control as well as interlocking test

□Yes □No

Verified by

Rema rks


(2)

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Items

Sequential control of auxiliary engine and interlock and protection tests

Requirements

Result

Air preheater(A/B) launching and tripping conditions, programmed start, programmed stop

□Yes □No

IDF(A/B) launching and tripping conditions, programmed start, programmed stop

□Yes □No

Forced draft fan (A/B) launching and tripping conditions, programmed start, programmed stop

□Yes □No

Primary air fan (A/B) launching and tripping conditions, programmed start, programmed stop

□Yes □No

Sealing fan (A/B) launching and tripping conditions

□Yes □No

Coal mill(A/B/C/D/E) launching and tripping conditions, programmed start, programmed stop

□Yes □No

Feeder (A/B/C/D/E) launching and tripping conditions

□Yes □No

(3)

I&C measuring points and meter of DAS system

The calibration is complted, the indication is accurate

□Yes □No

(4)

Protection, alarm as well as acoustic and light signals

It can give alarm after completion of transmission commissioning

□Yes □No

(5)

Emergency power supply

Applicable

□Yes □No

(6)

DCS two -way power

Applicable

□Yes □No

(7)

Blowing system control drawing

Completed for drawing

□Yes □No

3

Environmental conditions Traffic

Unclogging

□Yes □No

Light

Sufficient

□Yes □No

(2)

Communication equipments

Convenient and unobstructed

□Yes □No

(3)

Fire apparatus

Sufficient and in stand-by condition

□Yes □No

(4)

A/C system

It should be debugged to meet the requirement of the computer equipment

□Yes □No

(5)

Boiler staircase

Only after debugged and tested, it can be put into application.

□Yes □No

(1)

4


Other requirements

Verified by

Rema rks


(1)

(2)

(3)


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Items

Inspection


Resources preparation

Requirements

Result

Organizing the united major inspection on construction, Owner, production and commissioning; the problems found should be dealt completely.

□Yes □No

Completion of reparation for production commissioning

□Yes □No

Qualified training test of the operators

□Yes □No

The operation scheme and system drawing have been reviewed and approved.

□Yes □No

Operation instrument and running log are complete.

□Yes □No

Chemicals and material preparation for trial use are in order

□Yes □No

Chemical water, fuel oil and coal design are prepared sufficiently.

□Yes □No

(4)


Prepared

□Yes □No

(5)

Commissioning control and organization system

Sound and clear division of work

□Yes □No

Verified by

Rema rks


Appendix 2 No.

1


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Record list for blowing acceptance

Technical Requirements

Implementation

Inner diameter of temporary pipe is equal to or greater than C that of the upstream blowing pipeline

2

Blowing pressure is 5.5～6.5Mpa, and superheating temperature is 350℃～450℃

3

Time to open or close the blowing control motorized valve is less than 60S Blowing scope (1)Superheater, main steam pipelines, reheater pipelines of cold section , reheater pipeline of hot section, reheater

4

(2) HP/LP bypass pipeline pf steam turbine (3) Desuperheating water pipeline of superheater (4) Such other pipelines as shaft seal gas sources of steam turbine

5

During the process of blowing, time for shutdown cooling should not be less than 12h

6

Blowing coefficient of flow method is greater than 1

7

Record for total frequency of blowing Material and dimension of target

8

The length is equal to the inner diameter of the pipe where the target is installed The width is 8% of the length Material of target is aluminum Qualified target

9

Quantities of spot in size of 0.2～0.5mm in size

C

Quantities of spot is bigger than 0.5mm in size.

Commissioning Contractor

Contractor:

Date:

Date:


Dongfang Electric:

Date:

Date:

Remarks

Appendix 3

Record Table for Blowing Parameters Parameters when opening the control valve

No.

Time

Drum pressure MPa

Outlet pressure of super heater MPa

Temperature for main steam ℃

Parameters when closing the control valve Drum pressure MPa

Outlet pressure of super heater MPa

Inlet pressure of reheater MPa

Parameters in the process of blowing Maximal pressure difference of super heater MPa

Maximal pressure difference of reheater MPa

Exhaust steam pressure MPa

Remark s

Appendix 4

Blowing Diagram

Appendix 5

Blowing Diagram for Desuperheating water Pipeline of SuperHeater or Reheater

Appendix 6

Processing Diagram of Grain Collector

Appendix 7

Checklist for Motorized Valve of Steam-Water System

KKS code

Name

Motorized Valve Commissioning Record Remote Local position Direc Feed indication tion back

X0LAB40AA001

BOILER FEED WATER MOTORIZED VALVE

X0LAB40AA002

BOILER FEED WATER MOTORIZED ORIFICE VALVE

X0LAB41AA001

BOILER FEED WATER BYPASS CONTROL VALVE FRONT MOTORIZED VALVE

X0LAB41AA002

BOILER FEED WATER BYPASS CONTROL VALVE BACK MOTORIZED VALVE

X0LAB40AA401

BOILER FEED WATER VALVE FRONT DRAINING MOTORIZED VALVE

X0LAB40AA402

BOILER FEED WATER VALVE BACK DRAINING MOTORIZED VALVE

X0LAB44AA001

ECONOMIZER RECIRCULATING MOTORIZED VALVE A

X0LAB44AA002

ECONOMIZER RECIRCULATING MOTORIZED VALVE B

X0LCQ52AA001

ROOF SUPERHEATER INLET HEADER DRAINING MOTORIZED VALVE

X0LBA10AA501

OPEN SUPERHEATER START-UP EXHAUST MOTORIZED VALVE 1

X0LBA10AA502

SUPERHEATER START-UP EXHAUST MOTORIZED VALVE 2

X0LBB10AA501

REHEATER START-UP EXHAUST MOTORIZED VALVE 1

Time Direc tion

Feed back

Remot e

Date

Signatu re

Remark s

X0LBB10AA502

REHEATER START-UP EXHAUST MOTORIZED VALVE 2

X0LAF60AA001

REHEATED STEAM DESUPERHEATING WATER MAIN PIPE MOTORIZED VALVE

X0LAF61AA001

REHEATED STEAM EMERGENCY DESUPERHEATING WATER MOTORIZED VALVE

X0LAF62AA001

A SIDE REHEATED STEAM DESUPERHEATING WATER MOTORIZED VALVE

X0LAF63AA001

B SIDE REHEATED STEAM DESUPERHEATING WATER MOTORIZED VALVE

X0LCQ21AA001

DRUM EMERGENCY DRAINING MOTORIZED VALVE 1

X0LCQ21AA002

DRUM EMERGENCY DRAINING MOTORIZED VALVE 2

X0LCQ52AA001


X0LCQ53AA001

REAR ENCLOSURE RINGED HEADER DRAINING MOTORIZED VALVE 1

X0LCQ53AA002


X0LCQ53AA003

REAR ENCLOSURE RINGED HEADER DRAINING MOTORIZED VALVE3

X0LCQ53AA004


X0LCQ54AA001

WALL TYPE REHEATER INLET HEADER DRAINING WATER MOTORIZED VALVE 1

X0LCQ55AA001

ECONOMIZER INLET HEADER DRAINAGE WATER MOTORIZED VALVE

X0LCQ56AA001

WALL TYPE REHEATER INLET HEADER DRAINING WATER MOTORIZED VALVE 2

X0LCQ57AA001

FEED WATER OPERATION PLATFORM DRAINAGE WATER MOTORIZED VALVE

X0LAB40AA401

BOILER FEED WATER VALVE FRONT DRAINING MOTORIZED VALVE

X0LAB40AA402

BOILER FEED WATER VALVE BACK DRAINING MOTORIZED VALVE

X0LCQ52AA001


X0LCQ31AA001

BOILER FRONT WATER WALL INTERMITTENT BLOWDOWN MOTORIZED VALVE 1

X0LCQ31AA002


X0LCQ31AA003


X0LCQ31AA004 XB


X0LCQ31AA005


X0LCQ31AA006


X0LCQ32AA001

BOILER B SIDE WATER WALL INTERMITTENT BLOWDOWN MOTORIZED VALVE 1

X0LCQ32AA002


X0LCQ32AA003


X0LCQ32AA004 XB


X0LCQ32AA005


X0LCQ32AA006


X0LCQ33AA001

BOILER REAR WATER WALL INTERMITTENT BLOWDOWN MOTORIZED VALVE 1

X0LCQ33AA002


X0LCQ33AA003


X0LCQ33AA004

OPEN BOILER REAR WATER WALL INTERMITTENT BLOWDOWN MOTORIZED VALVE 4

X0LCQ33AA005


X0LCQ33AA006


X0LCQ34AA001

BOILER A SIDE WATER WALL INTERMITTENT BLOWDOWN MOTORIZED VALVE 1

X0LCQ34AA002


X0LCQ34AA003


X0LCQ34AA004


X0LCQ34AA005


X0LCQ34AA006


X0LCQ41AA002

BOILER FRONT WATER WALL INTERMITTENT BLOWDOWN MAIN MOTORIZED VALVE

X0LCQ42AA002

BOILER B SIDE WATER WALL INTERMITTENT BLOWDOWN MAIN MOTORIZED VALVE

X0LCQ43AA002

BOILER REAR WATER WALL INTERMITTENT BLOWDOWN MAIN MOTORIZED VALVE

X0LCQ44AA002

BOILER A SIDE WATER WALL INTERMITTENT BLOWDOWN MAIN MOTORIZED VALVE


Contractor:

Date:

Date:


Dongfang Electric:

Date:

Date:

Appendix 8

Checklist for Control Valve of Steam-Water System

KKS code KKS code

Control Valve Commissioning Record Feedback corresponding to input value while rising and falling

Description Name

0%

X0LAB41AA101

BOILER FEED WATER BYPASS CONTROL VALVE

X0LAF61AA101

REHEATED STEAM EMERGENCY SPRAYING WATER CONTROL VALVE

X0LAF62AA101

A SIDE REHEATED STEAM SPRAYING WATER CONTROL VALVE

X0LAF63AA101

B SIDE REHEATED STEAM SPRAYING WATER CONTROL VALVE

X0LCQ11AA101

BOILER CONTINUOUS BLOWDOWN FLASH TANK LEVEL CONTROL VALVE

X0LCQ20AA101

INTERMITTENT BLOWDOWN PIT INLET CONTROL VALVE


Contractor:

Date:

Date:

25%

50%

75%


Dongfang Electric:

Date:

100%

75%

Date:

50%

25%

0%

Inspecti on date Date

Result Result

Signature Signature

Remarks Remarks



PT.PLN(PERSERRO) PT REKADAYA ELEKTRIKA

Approval Review Date

Owner’s DWG No.

0702-00-M-01-LB-002


CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY DETAIL SiChuan Electric Power PLTU 1 Jatim-Pacitan DESIGN Commissioning & Test (2×315MW) Project STAGE Institute Check Procedure of Relief Valve and Steam Tightness System Design SCCTI-TS-GL-C REV N/A A Scale DWG No. S-017-2009A


Procedure of Relief Valve and Steam Tightness System

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PURPOSE ........................................................................................................................................... 3

2.

SCOPE ................................................................................................................................................ 3

3.


4.


5.


6.


7.


8.


9.

8.1

Steam Tightness Test ............................................................................................................ 7

8.2

Safety relief valve calibration .............................................................................................. 8

8.3

Putting the safety relief valves into operation .................................................................... 10

8.4

Complete trial operation record: ........................................................................................ 10

SAFETY MEASURES..................................................................................................................... 11 9.1

Safety Rules for Commissioning........................................................................................ 11

9.2

Personal Risk and Preventative Measures.......................................................................... 11

9.3

Equipment Risk and Preventative Measures ...................................................................... 11

9.4

Safety Precautions.............................................................................................................. 12 APPENDIX ............................................................................................................................... 13

10. 10.1

Appendix 1 Commissioning Condition Checklist.............................................................. 14

10.2

Appendix 2 Setting Record of Safety relief Valves and ERV ............................................ 17



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1.

Purpose

1.1

The steam tightness test means to have these items completely inspected, such as all heat surfaces of the boiler proper, steam and water pipelines, headers, all flanges, welding joints, etc., as well as boiler’s expansion system, stress, displacement and extension of all supports and hangers to ensure a safe and reliable operation of the unit.

1.2

Since the safety relief valves installed on the drum, superheater, reheater are the important safeguard facilities for the boiler, the hot state test and regulation for them should be carried out before the trial operation of the whole set of the boiler to ensure accurate and reliable action of them needed for safe operation of the unit.

2.

Scope The procedures described herein is applicable to tightness tests for the safety relief valves and steam system that includes boiler steam tightness test, settings of the safety relief valves for the drum, superheater and reheater, as well as the ERV trial operation.

3.

Preparation Basis

3.1

Summary sheet for set points of safety relief valves and quantity discharged for the boiler;

3.2

Boiler operation manual;

3.3

Manual of boiler performance and structure;

3.4

Instruction manual for installation and maintenance of safety relief valves.

4.

Brief Description of System and Equipment The boiler is to be provided with 12 American Consolidated safety relief valves, of which 3 are for steam drum, 2 for superheater outlet, 4 for reheater inlet, 2 for reheater outlet, and 1 EBV electromagnetic relief valve. Refer to the table below for the setting of safety relief valves and relief valves: No.

Installation location and No.

No.

Setting Pressure(MPa)

Discharge (t/h)

1

Steam drum 1# safety relief valve

1749WB

19.57

272

2


1749WB

19.96

280

3


1749WB

20.16

284

4

Superheater outlet 1# safety relief valve

1730WD

18.25

114

5

Superheater outlet 2# safety relief valve

1730WD

18.28

114

3538W

18.07

154

6

Superheater outlet electromagnetic relief valve (ERV)



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7

Reheater inlet 1# safety relief valve

1785WB

4.37

177

8


1785WB

4.37

177

9


1785WB

4.50

182

10


1785WB

4.50

182

11

Reheater outlet 1# safety relief valve

1765WD

4.01

67

12

Reheater outlet 2# safety relief valve

1765WD

4.325

72

The information contained in the above list sources form the Instruction Manual of Dongfang Boiler of DEC (No. 97M-YM)

5.


5.1

Walkie talkie；

5.2

Master pressure gauge；

5.3

Hydraulic setting device；

5.4

Tool kit.

6.

Prerequisite for Commissioning Before formally beginning safety relief valve setting and commissioning, commissioning persons should conduct comprehensive checks on conditions that should be available for commissioning of this system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and make well the records.

6.1


6.1.1

Safety relief valve system

6.1.2

(1)

Erection work for all safety relief valves of the system has been completed.

(2)

Exhaust steam pipe and silencer have well been fixed and bear a reasonable stress. Foreign matters inside them have been cleaned away.

(3)

The drain pipe of safety relief valves is clear and smooth.

(4)

Cold test work for safety relief valves has been completed.

Boiler proper and its auxiliary system (1)

Hydraulic test of boiler is satisfied.

(2)

Expansion clearance between relative sections of the boiler has a reasonable value. All expansion indicators are fully equipped and their zero point at the cold condition has been set.

(3)

Boiler steam-line blowing has been finished.

(4)

Commissioning work for all subsystems, such as coal pulverizing, air and flue gas ducts,



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feed water, fuel oil, ash and cinder removal, etc. has been completed.。 6.1.3

6.2

6.3

6.4

Turbine system (1)

Turbine’s high and low pressure bypass system is ready to be put into regular service.

(2)

Shaft jacking and turning system and condenser vacuum system of the turbine are ready to be put into regular service.


Interlock protection test for the boiler has been completed.

(2)

Driving test of electrical and I&C loop for ERV has been completed. All hand-operated valves have a reliable operation. Pressure switches have been correctly set and are putting at the calibration state.。

(3)

All electrical and I&Cs have been calibrated and have accurate indication.

(4)

The master pressure gauges with accuracy class of 0.4 and measuring range of 0-25 MPa and 0-6 MPa have been calibrated for satisfaction and installed.

Environmental conditions needed (1)

All execution at the commissioning site has been completed with the platform free from foreign matters and passage should be kept smoothly.

(2)

The temporary structure of platform and safety guards needed for safety relief valves

(3)

The temporary platform and safety guards for calibration of safety relief valves has been constructed and prove to be safe and reliable.

(4)

The site should have a permanent and sufficient light supply, and some temporary lighting points shall be added when needed.

(5)

There should be complete and reliable communication equipment at the site..

Other conditions needed The overall inspection with joint participation of all parties of construction, builder, Owner, operation, commissioning, etc. should be carried out and any problems discovered should be solved to make sure that the requirement for the boiler ignition has been met. (1)

All preparation work for the trial operation is completed, and all operators have been appointed and be qualified through training courses and examinations. The operating standard and applicable system diagram has examined and approved, and the tools and forms of operational logs for the operation have been prepared.

(2)

Chemicals and materials needed for the trial operation and sufficient chemical water, fuel oils and coals meeting the design requirement have been well prepared.

(3)

Special tool kit for the calibration should be well prepared.

(4)

Prepare the tools and materials needed for the maintenance.

(5)

Have a sound command organization with definite duties and responsibilities to direct the trial operation.

(6)

The technical information, tools, instrument and the record forms have all been prepared.


7.


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(7)

The personnel of the installation contractor in charge of instrument & control, electrical and turbine & boiler sections are all presence at the site.

(8)

Technical service personnel from the manufacturer of safety relief valves are presence at the site.


7.1

7.2

7.3



◆


◆


◆


◆


◆


◆




◆


◆


◆


◆

Be responsible for setup and removal of temporary test platform;

◆



7.4




◆


◆



7.5

7.6


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◆


◆

Be responsible for dealing with the accidents occurred in commissioning.



◆


◆


◆




◆


◆


8.


8.1

Steam Tightness Test

8.1.1

Supply the boiler with feed water to the normal level.

8.1.2

Boiler ignition: Have the boiler ignited and boosted in accordance with the standard :Operating Code for Boiler. (1)

Rate of temperature and pressure boost should be controlled according to the rules below:

Pressure of main steam (MPa)

<0.98

0.98--3.92

3.92--9.8

9.8--18.2

Rate of temperature rise (℃/h)

<28

<56

≤30

≤36

Pressure boost rate of (MPa/min)

──

≤0.03

≤0.05

≤0.06

(2)

The burning and related drain valve opening should be adjusted from time to time during the period of boiler ignition and pressure boost.

(3)

The thermal expansion values at the following conditions and pressure points shall be recorded: before feed water supplying, after feed water supplying, 0.3~0.5MPa, 1.0~1.5MPa, 5.0~6.0MPa, 9.0~10.0MPa, 12.0~13.0MPa, 14.0~15.0MPa, 16.0~17.40 MPa. If it is found that the normal expansion has been obstructed during above procedures, stop temperature and pressure boost, and no any operation for further temperature and pressure boost shall be allowed before the reasons detected and eliminated. In addition, the special attention should be given to the relative expansion of wall-type reheater to the water wall and lower section of the boiler.

(4)

Manually open the ERV to do the operation test of it and steam exhaust valves of superheater (reheater). Also carry out the operation test for the control valves of high



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and low pressure bypass system. The overpressure of the boiler should be avoided during the continuous pressure boost and any possible accident should be envisioned and have the countermeasures considered in advance. (5)

8.1.3

When the main steam pressure raised to 10MPa/15MPa, have the boiler proper fully checked to make sure no any uncommon conditions to be found and then go ahead with pressure boost.

When the pressure at the outlet of boiler superheater raised to 17.1MPa-17.4MPa, have the tightness for the superheated steam system tested and have the following items checked by using the observing and hearing method: (1)

Tightness of welding seams on all pressure containing members of the boiler, man holes, flanges, etc.;

(2)

Tightness of all steam and water valves of the boiler;

(3)

Expansion conditions of drum, headers, members of all heat surfaces and steam /water pipelines within the range of the boiler, as well as the stress conditions of supports, hangers and their springs.

8.1.4

After the tightness test for the boiler superheat steam system completed, lower the drum pressure to 15MPa (as requested by the manufacturer) and be ready for the setting of safety relief valves of the drum and superheater.

8.1.5

After setting of safety relief valves on the drum and superheater, have the outlet pressure of reheater raised to 3.80-3.81MPa by means of a proper opening of high and low bypass valves of the turbine to have the tightness of reheat steam system checked.

8.1.6

Have tightness of the reheat steam system tested to have the following items checked by using the observing and hearing method: (1)

Tightness of welding seams and flanges of reheat steam system;

(2)

Tightness of all steam and water pipelines and valves of the reheat steam system;

(3)

Expansion conditions of headers, members of all heat surfaces and steam /condensate drain pipelines, as well as the stress conditions of supports, hangers and their springs.

8.1.7

After the above checks, lower the pressure to 3.5-4.0MPa and have it stabilized to conduct the calibration of the safety relief valves at inlet and outlet of the reheater.

8.1.8

Conduct real actuating test of safety relief valves of the superheater and reheater system.

8.1.9

If the above test is satisfied have the ERV calibrated, otherwise, have it tested again until it is satisfied.

8.2

Safety relief valve calibration

8.2.1

Preparation before the test

8.2.2

(1)

The master gauges for the setting of safety relief valves (with accuracy class better than 0.4, and one for 0-25WPa, one for 0-6WPa) have well been calibrated and installed.

(2)

Have the following items well prepared: tools, hydraulic setting device, string for pulling the handle, communication equipment, recorder, etc.

For the smooth and safe operation of safety relief valves settings firstly make sure that the following work have been finished for satisfaction: (1)

The steam tightness test has been passed;


8.2.3

8.2.4


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(2)

The platform, passage, lighting and communication meet the requirement for setting of safety relief valves and all items needed for the adjustment have well been prepared;

(3)

Manually open the ERV to do the operation test of it and steam exhaust valves of superheater and reheater;

(4)

Carry out the operation test for the control valves of high and low pressure bypass system;

(5)

Have the safety relief valves adjusted under the conditions of taking only oil as the fuel and no coal shall be allowed (or only a little amount of coal);

(6)

Have the organization system of “division of responsibilities” set up and every operator should be present at the site and shall go about their respective items.

The acceptable quality level for calibration of the safety relief valves (1)

Have the actual action proof test for one safety relief valve chosen from each system after the calibration for all safety relief valves have been completed.

(2)

Deviation limit of actual actuating pressure from the designed values shall be ±1%.

(3)

The difference between actual re-seating and the popping pressure should be 4%-7% of the popping one and not more than 10% at most.

Setting procedures for the safety relief valves The setting of safety relief valves shall be operated sequentially from higher pressure to the lower ones. Firstly assemble the holddown mechanism for all safety relief valves of drum, superheater and reheater (except pending ones) and then close the isolation valve at inlet of EBV valve. Put the safety relief valves, which has well been set, into operation instantly.

8.2.5

(1)

Tightness test for the superheated steam system;

(2)

Setting of drum’s safety relief valves;

(3)

Setting of superheater’s safety relief valves;

(4)

Actuating test for the safety relief valves of superheat steam system

(5)

Operation test for ERV

(6)

Steam tightness test for the reheater system;

(7)

Setting of safety relief valves at the inlet of reheater;

(8)

Setting of safety relief valves at the outlet of reheater;

(9)

Actuating test for safety relief valves of reheater system;

Setting method for the safety relief valves of drum and superheater (1)

Before calibration, lift the lever with help of a tool and let the safety relief valve to be purged by discharging steam for thirty (30) seconds. After purge release the lever immediately to check the expansion of steam-discharge tube and other parts of the safety relief valve, and handle the problems discovered promptly.

(2)

Conduct the setting for safety relief valves of drum and superheater by using the hydraulic setting device.

(3)

Maintain a stable combustion of the boiler and adjust the system pressure by using high and low pressure bypass system to keep the pressure as stable as possible.

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure (4) 8.2.6

8.2.7

8.2.8

8.2.9

8.3


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Setting of safety relief valves and calibration of pressure gauges of DCS shall be based on the local master gauge.

Actuating test for safety relief valves of the boiler superheater system (1)

Principle for safety relief valve actuating test: the safety relief valve at the outlet of superheater with the lowest actuating pressure value shall be selected as the subject. The burning shall be controlled to make the valve returned after the valve popped during the test. If the tested valve could not be returned for some reason of itself, report the case immediately and take some measures.

(2)

If a slight leak of any safety relief valve discovered in the above test and the system pressure still maintained then the test could be continued till its end and shut down the boiler to handle the case.

Operating test of ERV (1)

Contact related department to make ERV energized, open the hand-operated valve at the inlet of ERV.

(2)

When the main steam pressure stepped up to about 15~16MPa, make the ERV popped by hand to discharge the steam for about thirty (30) seconds and then close it.。

(3)

Step up the pressure to the actuating value of ERV to check for a correct one. If the actual actuating value has a larger deviation from the set point, the pressure control switch has to be re-calibrated.

Setting of Reheater safety relief valves (1)

Lower the main steam pressure to 8.0~10.0MPa and conduct the setting of safety relief valves of reheater system by adjusting the pressure of the reheater using the high and low pressure bypass system.

(2)

Before calibration, lift the lever with help of a tool and let the safety relief valve to be purged by discharging steam for thirty (30) seconds. After purge release the lever immediately to check the expansion of steam-discharge tube and other parts of the safety relief valve, and handle the problems promptly if discovered.

(3)

Lower the reheater pressure to 3.5~4.0MPa and have it stabilized.

(4)

Setting of reheater safety relief valves shall be operated sequentially from higher pressure to the lower ones, and from one used at the inlet to the one used at the outlet..

Actuating test for the safety relief valves of reheater steam system (1)

Principle for safety relief valve actuating test: the safety relief valve at the outlet of reheater with the lowest actuating pressure value shall be selected as the subject. The burning shall be controlled to make the valve returned after it popped during the test. If the tested valve could not be returned for some reason in itself, report the case immediately and take some measures.

(2)

If a slight leak of any safety relief valve discovered in the above test and the system pressure still maintained then the test could be continued till its end and shut down the boiler to handle the case.。

Putting the safety relief valves into operation Remove all holding down clips and put all safety relief valves into operation after the actuating test of them completed and accepted as satisfactory.

8.4

Complete trial operation record:



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For the setting values of the safety relief valves refer to Appendix 2

9.

Safety Measures

9.1


9.1.1


9.1.2


9.1.3


9.1.4

The process of temperature rise and pressure boost shall be conducted in accordance with the related curves for temperature rise and pressure boost.

9.2


The places where the safety relief valves installed It is possible that the operators might be scalded by steam during procedures of safety relief valves setting causing a serious injury. To avoid this, the safety isolating measures should be considered and a skilled operator shall specially be designated to be responsible for the work. There should be smooth passsage and sufficient lighting around the safety relief valve, reliable communication facilities and temporary platform if necessary. Any one who has nothing to do with the work shall be asked to evacuate the site and any possible accident should be envisioned in advance by operators taking part in the commissioning.

The pressurized system and pipelines The hydraulic test for the boiler should be satisfied and any leaks discovered should be eliminated; The commissioning of the safety relief valves shall be conducted after the tightness test for all pipelines completed and prove to be satisfactory.

Equipment damage and/or personal injury caused by over temperature and/ or overpressure During the period of safety relief valve commissioning the fuel should be input slowly and steadily for a stabilized pressure, and overpressure shall be prohibited. Special attention should be given to the monitoring of wall temperature and the temperature of the position where the temperature probes have been installed. If the burning rate is out of control, shut down the boiler immediately. Any possible accident should be envisioned in advance

9.3


Malfunction of water level protection Set the drum level protection inhibited before setting of the safety relief valves to avoid the boiler’s main protection actuated caused by a false water level during the actuating test of the safety relief valves.



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Misoperation for the test The commissioning of safety relief valves should be operated by the skilled operators. Have the pressure lowered and the holddown mechanism properly installed before the test.

Abnormal operation of equipment If it is found that an operating equipment emits abnormal sound or has other abnormal condition, and such problem may not be eliminated, stop such equipment and report to the control rooms immediately.

Equipment damage caused by burning of accumulated coal dust at the tail end Have the pulverized coal periodically analyzed and keep the coal fineness within the range specified. Have the combustion carefully adjusted and have the soot blowers for the air preheater operated uninterruptedly for good burning conditions. Maintain a normal level and have the closed system purged with a heavy flow of air after the boiler shutdown. In addition, enhance the monitoring of the flue gas temperature at the boiler’s tail and handle the problem discovered promptly. Have the ash accumulated at the boiler’s tail area checked irregularly and have the boiler purged with a large amount of air before restart. Temporary fire installation shall be equipped at the tail end of the boiler. Have a special operator monitored and have the fire water system kept at a serviceable condition.

9.4

Safety Precautions

Oil should be used as the fuel of boiler during the whole procedures of the test to reduce pressure fluctuation and ensure a stable load of the boiler.

The process of temperature and pressure boost shall be conducted in accordance with the related curves for temperature and pressure boost to make sure that all heat elements of the boiler proper expanded freely. Have the temperature difference between upper and lower walls of the boiler and the temperature of reheater’s metal wall to make sure that they are within the range of prescribed limit. Strictly limit the temperature of flue gas at outlet of the furnace under 538℃ for the safe operation of the reheater.

The boiler’s blow-off valve should have a correct action and the high/low bypass system should be at the hot standby condition during the pressure boost procedures to keep ready for blowdown when overpressure occurs.

Pay special attention to the safety, any abnormalities shall be reported in time and stop the temperature and pressure boost to take measures to eliminate them for further procedures if necessary.

The observing and hearing method shall be used for inspection of the steam system tightness. Special attention should be paid for prevention of personal injury caused by leakage of any pressure containing member.

During the period of safety relief valves setting there should be a platform around the valve firm enough to support three operators. Any one who has nothing to do with the work shall be asked to evacuate the site.

Since the calibration of safety relief valve belongs to a kind of overhead work, the safety belt should be used there where the accident of falling from height might occur to avoid personal injury.

The operator should wear safety hemelt when working at the commissioning site. The project director should have the site analyzed to eliminate any potential hazard such as falling from height, electric shock and scald, as well as wringer injury caused by rotary



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machines.

10.

Set the drum level protection inhibited before setting of the safety relief valves to avoid the actuating of the boiler’s main protection caused by a false level. Pay attention to avoid the accident of “full of water” and “lack of water” of boiler when the safety relief valve actuated.

In case of the thrust screw, upper and lower adjustable rings or overlap collars need to be adjusted the work should be done by the manufacturer’s service man or skilled operator wearing the protective mask and heat resisting gloves.

In case of any safety relief valve could not be returned after actuating shutdown the boiler promptly for repair.

Have the auxiliary sootblowing for air preheater operated uninterruptedly and intimately monitor the temperature of flue gas at the tail end of the boiler.

Appendix


10.1

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Appendix 1 Commissioning Condition Checklist

No. 1


Items

Requirements

Result

Installation work of all safety relief valves in the system have been finished.

□Yes □No

Exhaust steam pipe and silencer have well been supported and bear a reasonable stress. Foreign matters inside them have been cleaned away.

□Yes □No

The drain pipe of safety relief valves is clear and smooth.

□Yes □No

Cold test work for safety relief valves has been completed.

□Yes □No

Hydraulic test for the boiler is satisfied.

□Yes □No

Expansion clearance between relative sections of the boiler has a reasonable value. All expansion indicators are fully equipped and set their zero point at the cold condition.

□Yes □No

Boiler steam-line blowing has been finished.

□Yes □No

Commissioning work for all subsystems, such as coal pulverizing, air and flue gas ducts, feed water, fuel oil, ash and cinder handling, etc. has been completed.

□Yes □No

Turbine’s High and low pressure bypass system is ready to be put into regular service

□Yes □No

Shaft jacking and turning system and condenser vacuum system of the turbine are ready to be put into regular service.

□Yes □No

Conditions of the turbine and boiler

(1)

(2)

(3)

Safety relief valve System

Boiler Proper and Its Auxiliary System

Turbine Section

2

Electrical and I & C conditions

(1)

Interlock and Protection

Fulfilled

□Yes □No

ERV

Driving test of electrical and I & C loops have been completed. All hand-operated valves have a reliable operation. Pressure switches have been correctly set and are putting at the calibration

□Yes □No

(2)

Verified by

Remarks



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Page 15 of 18

state. (3)

(4)

Steam and Water System

Master Gauge

Electrical and heat power engineering instrument have been calibrated and prove to be accurate.

□Yes □No

To be calibrated for satisfaction

□Yes □No

3


(1)

Site Platform Passage

All work has been completed. Free of foreign matters. To be kept smoothly.

□Yes □No

(2)

Temporary Platform and Safeguards

The construction work finished and prove to be safe and reliable.

□Yes □No

(3)

Lighting

Sufficient, and temporary lighting points added when necessary.

□Yes □No

(4)

Communication System

Reliable

□Yes □No

4

Other conditions

(1)

Inspection

The overall inspection with joint participation of all parties of construction, builder, Owner, operation, commissioning, etc. should be carried out and any problems discovered should be solved.

□Yes □No

Trial operation has well been prepared.

□Yes □No

Operators have well been trained and have passed the exam.

□Yes □No

The operating standard and applicable system diagram has examined and approved.

□Yes □No

Tools and forms of operational logs for the operation have well been prepared.

□Yes □No

Chemicals and materials needed for the trial operation have well prepared.

□Yes □No

Sufficient chemical water, fuel oils and designed coals have well been prepared.

□Yes □No

(2)

(3)

Production Preparation

Resources Preparation

(4)

Special Tool Kit for the Calibration

Have well been prepared.

□Yes □No

(5)

Overhaul Tools and Materials

Ready for use

□Yes □No

(6)

Command Organization for Trail Operation

To be sound and with definite duties and responsibilities.

□Yes □No



REV A


Page 16 of 18

(7)

The technical information, tools, instrument and the record forms

Ready for use

(8)

Personnel of the installation contractor in charge of instrument & control, electrical and turbine & boiler sections

In place

Technical service personnel from the manufacturer of safety relief valves

In place

(9)


Date:

□Yes □No

□Yes □No

Date:

□Yes □No



Date:

Date:


10.2


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Page 17 of 18

Appendix 2 Setting Record of Safety relief Valves and ERV

Setting Record of Safety relief Valves and ERV Drum safety relief valves parameter Setting pressure Service

Description

(MPa)

1

1749WB

19.57

2

1749WB

19.96

3

1749WB

20.16

Popping pressure

Return pressure

(MPa)

(MPa)

Remarks

SH safety relief valves parameter Setting pressure

Popping pressure

Return pressure

(MPa)

(MPa)

Setting pressure

Popping pressure

Return pressure

(MPa)

(MPa)

(MPa)

Service

Description

(MPa)

1

1730WD

18.25

2

1730WD

18.28

Remarks

ERV Service

Description

1

3538W

Remarks

18.07 RH inlet safety relief valves parameter Setting pressure

Service

Description

(MPa)

1

1785WB

4.37

2

1785WB

4.37

3

1785WB

4.50

4

1785WB

4.50

Popping pressure(MPa)

Return pressure (MPa)

Remarks

RH outlet safety relief valves parameter Setting pressure

Popping pressure

Return pressure

(MPa)

(MPa)

(MPa)

Service

Description

1

1765WD

4.01

2

1765WD

4.325


Date:

Date:



Date:

Date:

Remarks



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Page 18 of 18

PLTU 1 Jatim-Pacitan (2 × 315MW) Project


PT.PLN(PERSERRO)

Owner’s DWG No.




Check Design Scale


DETAIL DESIGN STAGE

Procedure of Cold State Aerodynamic Field N/A

DWG No.


REV

A


Procedure of Cold State Aerodynamic Field


REV A Page 2 of 20

Table of Contents

1.

PURPOSE ........................................................................................................................................... 3

2.

SCOPE ................................................................................................................................................ 3

3.


4.


5.


6.


7.

ORGANIZING MEASURES OF COMMISSIONING .................................................................. 5

8.


9.

SAFETY MEASURES..................................................................................................................... 11

10.

9.1

Safety rules for commissioning...................................................................... 11

9.2

Personal Risk and Preventative Measures ................................................... 11

9.3

Equipment Risk and prevention measures .................................................. 11 APPENDIX ............................................................................................................................... 11

Appendix 1

Commission Condition Checklist ........................................................ 12

Appendix 2

Record list of leveling test data for primary air coal pulverized pipe

........................................................................................................................................ 15 Appendix 3

Record list of test parameter for aerodynamic field.......................... 16

Appendix 4

Erection drawing of scaffolding platform for aerodynamic field in

boiler .............................................................................................................................. 19




REV A Page 3 of 20

1.

Purpose

1.1

To master distribution, diffusion and flow conditions of gas in the boiler.

1.2

To understand switching air quantity characteristics of various dampers and resistances of combustion system and burners.

1.3

To understand size of inscribed circle and gas flow fullness in four-corner firing boiler and gas flow conditions of burner nozzle.

2.

Scope This Procedure is applicable to commissioning of cold state aerodynamic field. The scope of commissioning includes:

2.1

Installation, measurement and calibration of burners;

2.2

Adjustment of burner damper;

2.3

Installation of various air speed measuring elements and arrangement of measuring grids in boiler;

2.4

Calibration of factor for primary air speed-measuring pipe;

2.5

Adjustment and leveling primary air speed, as well as damper characteristic test;

2.6

Secondary air damper characteristic test;

2.7

Test of velocity field in boiler;

2.8

Test of furnace outlet velocity field under various operating conditions;

2.9

Flame tracing test in boiler.

3.

Preparation Basis

3.1

Flow chart of flue-gas and air system;

3.2

Schematic diagram of burner structure;

3.3

Manual of combustion equipment；

3.4

Summary Table of boiler thermal design.

4.

Brief Description of System and Equipment In this project, three sub-critical, four-corner tangential firing, natural circulation, steam drum boilers will be installed. The boiler is of single furnace, semi-outdoor design, lignite, primary reheating, balanced ventilation and solid deslagging. The model of such boiler is DG1025/18.3-II13. The combustion equipment is louver-type and horizontal dense-sparse swing type straight flow burner in manner of four-corner arrangement and tangential firing; where centerline of burner nozzle is tangent to both virtual circles of furnace center; the diameters of the two virtual tangential circles are Φ1032mm and Φ548mm respectively; coal pulverizing system is of medium speed coal mill cooling primary air fan positive pressure direct firing. The model of coal mill is HP963 and in total fiver coal mills are provided (four for operating and one for standby); fineness of pulverized coal (R90): Design coal type 32%. Burner Characteristic Data (design coal type under BMCR)


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Page 4 of 20

Item

Air speed（m/s）

Primary air

28

65

1900

Secondary air

45

346

1000

Perimeter air

35

346

—

Leaked air of furnace

—

Cold air

—

Air temperature（℃） Resistance（Pa）

Details will be given after providing the instruction.

5.


5.1

Walkie-talkie

5.2

Vibration measurement instrument

5.3

Anemoscope

5.4

Pitot tube

5.5

U-shaped tube

5.6

Emulsion tube

5.7

Sufficient tracing streamer

5.8

Special spanner

6.

Prerequisite for Commissioning Before formally starting system commissioning, commissioning personnel shall carry out overall inspection on prerequisites for this commissioning listed in Appendix 1 (commissioning prerequisites checklist), and make a proper record.

6.1

Test equipment and material must be checked for a proper condition before test.

6.2

Cold modeling calculation is fulfilled.

6.3

Before test, inspect and measure burner nozzle dimension and mounting angel.

6.4

Air-measuring platform and lightings in boiler and primary air speed leveling platform outside boiler are installed, accepted and eligible.

6.5

All measuring points for the test have been installed.

6.6

Individual trial operation of forced draft fan, induced air fan and primary air fan is over and corresponding procedures have been fulfilled.

6.7

Installation and commissioning of flue-gas and air system, pulverized coal pipe and dampers on pipe are over.

6.8

Air pressure test of furnace and flue-gas and air system is eligible and insulation is over.

6.9

Works for boiler’s flue-gas and air system and coal pulverizing system and in boiler are over; there has no foreign matter.

6.10

Temperature and pressure measuring elements within flue-gas and air system and furnace negative pressure measuring elements are tested and eligible; commissioning is over.

6.11

Damper actuation test of coal pulverizing system and flue-gas and air system is over.

6.12

The center in boiler at specified elevation has been fixed with fine wire to show its


REV A



Page 5 of 20

coordinates. 6.13

Burning powder online device is installed and equipment manufacturer has arrived at site and is prepared for calibration.

7.

Organizing Measures of Commissioning The Procedures shall be carried out under organization of commissioning contractor. Related units for this project shall closely cooperate each other according to respective responsibilities and work division, thus to ensure safe and high-efficiency commissioning. See following for respective responsibilities and work division of various units:

7.1

7.2



◆


◆


◆


◆


◆


◆




◆


◆


◆ Assist the commissioning contractor in the commissioning of subsystems；

7.3

◆

Be responsible for erection and removal of test platform

◆

Be responsible for temporary coordination of local I&Cs and connection terminals.


7.4


Responsibilities of Operation Department ◆


◆


◆


◆ Be responsible for patrol inspection, check, and normal maintenance of system and equipment;


REV A



Page 6 of 20

◆ Be responsible for dealing with the accidents occurred in commissioning。 7.5

7.6



◆


◆


◆




◆


◆ Accept the results of commissioning。

8.


8.1

Test Content and Method

8.1.1

Preparation for Testing

（1） Measurement of mounting angle for burners Before formal test, measure mounting angle for burners and compare it with design value, and correct it in case of large deviation. The measurement shall be made in manner of triangular method, namely create a triangle horizontally at the place of burner nozzle, measure the lengths of various sides, and calculate included angle between nozzle and water-cooling wall with cosine law, and then determine its mounting angle. As shown in Fig. 1, respectively measure the lengths of AB, AC and BC, and

α = arcCosC = calculate mounting angle with the formula

2 2 2 a +b −c − 90 2ab

Fig. 1 Measurement of mounting angle for burners

（2） Adjustment of burner damper




REV A Page 7 of 20

Adjustment of burner damper includes adjustment of burner secondary dampers: auxiliary damper, fuel damper and top damper. It requires to achieving same opening for dampers at same layer, synchronized adjustment, actual opening corresponding to adjustment command, and even adjustment under commands for various openings.

（3） Fan enabling and air pressure adjustment After fulfilling above works, start up various rotating machines of flue-gas and air system, and regulate its pressure and flow, thus to meet the requirements of test conditions.

（4） Installation and calibration of air speed measuring elements Install and calibrate air speed measuring device “backrest tube” installed for primary air pipe. The calibration shall be carried out with standard Pitot tube and electronic micromanometer. Finally, speed correction factor K of backrest tube will be measured. Air speed for calibration test shall be within actual operating air speed.

（5） Primary air adjustment and leveling After installing and calibrating air speed measuring device for primary air pipe, carry out primary air adjustment and leveling. The leveling shall be carried out as per same layer, namely fully open dampers at same layer, adjust throttle plate on the corresponding pipes, thus to achieve same air flow for pipes at same layer and that flow deviation is within allowable range. The air quantity for adjustment and leveling shall be within the range for actual operating air speed. Cold state leveling is the basis of hot state operation. In case of hot state operation, it is still required to further carry out adjustment and leveling on air quantity of pipes on various layers.

（6） Damper characteristic test Damper characteristic test includes characteristic test for secondary air damper and primary air damper of burners. It is purposed to test that whether openings of various dampers are within 0%～100%; whether burner nozzle air speed is corresponding to damper opening; each damper shall be subject to test for 5 openings before mapping out damper characteristic curve finally. 8.2

Formal Test

8.2.1

Measurement of primary air speed Measurement of primary air speed is purposed to measure air speed of primary air nozzle, thus to ensure that primary air speed under cold state is within self-modeling zone and momentum ratio of primary air under cold state and hot state is equivalent. During the test, primary air pressure and openings of primary and secondary air dampers at various corners shall be controlled and maintained unchanged. Calibration factor shall be calculated with following formula:

K=

∑

K p Δ Pi n Δ Pd

In which: Kp------- Pitot tube dynamic pressure calibration factor 　Pi------- Dynamic pressure measured at various points with Pitot tube, mmH2O 　Pd------- Dynamic pressure measured with backrest tube, mmH2O


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Page 8 of 20

n--------- Total number of calibration measuring points Air speed of secondary air nozzle is obtained through measuring secondary air damper characteristic curve. Modeling air speed of secondary air nozzle under corresponding operating conditions is determined according to secondary air damper characteristic curve. See following for measurement arrangement of secondary air damper characteristic curve. Table３ #1 corner Opening secondary damper

of air

#2 corner

#3 corner

#4 corner

100%

0%

100%

0%

75%

25%

75%

25%

50%

50%

50%

50%

25%

75%

25%

75%

0%

100%

0%

100%

8.2.2

Cold state modeling test

8.2.2.1

Prerequisites for cold state modeling test

（1） Cold modeling air flow’s entering into self-modeling zone For four-corner arranged burners, critical Reynolds number Re for air flow’s entering into self-modeling zone shall follow following provisions: Primary air

1.48×105

Perimeter air

4.8×104

Secondary air

7.5×104

Furnace

7.5×104

（2） Geometrical similarity between the model and actual object The cold modeling test will be carried out on actual furnace; therefore, the similarity ratio between the model and actual object shall be 1.

（3） Equivalent momentum ratio for primary air, secondary air and perimeter air under cold and hot states

Maintain equivalent momentum ratio under cold and hot states and calculate primary air speed and secondary air speed with following formula:

W1M W10 t 20 + 273 × (1 + Kμ) = + 273 W2M W20 t10 Calculate the ratio between secondary air speed and perimeter air speed with


REV A



Page 9 of 20

following formula:

W zj M W zj 0 t 20 + 273 = W 2 M W 20 t zj 0 + 273 In which: W10, W20, Wzj0----

Speed of primary air, secondary air and perimeter air under hot states, m/s;

W1M, W2M, Wzj0------

Speed of primary air, secondary air and perimeter air for cold modeling, m/s;

t10, t20, tzj0-------

Temperature of primary air, secondary air and perimeter air under hot states, ℃;

K------

Correction factor considering different pulverized coal flow and air speed, taken as 0.8;

　------

Weight concentration calculation value for fuel in primary air: kg (pulverized coal) /kg (air).

（4） Determination of cold state modeling parameter Simulate burner operating parameter at hot state under various operating conditions: Table Operating conditions Air speed

BMCR Five coal mills operating

BMCR Four coal mills operating

Air speed of primary air nozzle m/s

28

28

Air speed of secondary air nozzle m/s

42

45

Air speed of perimeter air nozzle m/s

35

35

Concentration of primary air pulverized coal kg/kg

0.504

0.630

Air speed of cold state burner nozzle will be as follows when simulate above conditions: Table

Air speed of primary air nozzle m/s

BMCR Five coal mills operating

BMCR Four coal mills operating

18

18


8.2.3

REV A



Page 10 of 20

Air speed of secondary air nozzle m/s

26.7

29.2

Air speed of perimeter air nozzle m/s

20.3

20.1

Test of cold state velocity field Allow total air quantity entering into boiler greatly larger than that entering into self-modeling zone according to control air speed calculated based on cold modeling test principles,

（1） Measurement of velocity field in boiler Apply iron wire to create cross grid at primary air section in the boiler, and tie a white cloth strap for every 200mm, and form 64×2=128 measuring points in total. Measuring speed at various points, including the speed against the wall in boiler. The circle connecting maximum speed points will be cold modeling tangential circle. The test shall be carried out under rated operating conditions.

（2） Flame tracing test of aerodynamic field in boiler When aerodynamic field test is carried out in manner of flame tracing method, control speed of primary air and secondary air according to requirements in above table. Mount one special flame on each primary air nozzle and fire it layer by layer, thus to observe gas flow conditions in boiler.

（3） Test of furnace outlet velocity field Fix three iron wires at furnace outlet horizontal flue and measure distribution of velocity field. Airflow residual rotation under different operating conditions will be assessed according to average speed difference at left and right sides. Total measuring points for each operating condition shall be 64×3=192 points. Please refer to Table 6 for selection of test condition. Before test of furnace outlet velocity field, remove scaffolding for the purpose of camera at furnace outlet. Table 6 Operating condition

Description

#１

Rated condition, namely pulverized coal for all five layers input, five coal pulverizing systems operating, top counter-tangent secondary damper fully open.

#2

Pulverized coal for four layers input, four coal pulverizing systems operating, top counter-tangent secondary damper fully open.

#3

Pulverized coal for four layers input, four coal pulverizing systems operating, top counter-tangent secondary damper fully open.


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Page 11 of 20

9.

Safety Measures

9.1


9.1.1


9.1.2

In case of any accidents that damages the equipment or hurts person happened or possibly happen during commissioning, suspend commissioning immediately and put the equipment to the lowest energy state. Investigate the cause and take corrective measures.

9.1.3


9.2


9.2.1

Before test, ensure all working personnel in furnace, flue, air course and rotating equipment have been withdrawn.

9.2.3

Guard rail and guard net shall be installed, safety belt worn, and measures taken to prevent falling or injury by falling object in case of aloft work.

9.2.4

Test platform shall be solid and reliably without shaking and the ladder shall have proper distance between steps (able to bear the weight of 3-4 adults). Lightings in boiler are efficient and meet test requirements.

9.3

Equipment Risk and prevention measures

9.3.1

Test equipment and installation equipment shall be effectively isolated.

9.3.2

Power supply and cutoff shall be in strict compliance with related provisions.

9.3.3

The personnel participating in the test shall not operate the equipment to be tested without authorization. Adjustment of test conditions shall be fulfilled by operation personnel participating in the test according to predetermined test measures, only after test superintendent issues the command.

9.3.4

During the test, attention shall be paid to personal and equipment safety. The installation unit shall assign maintenance personnel to maintain various rotating machines and handle the problems in time if found; and I&C personnel to dispose and replace in time the transmitter and instrument with large deviation.

9.3.5

Operation personnel shall carefully monitor, so as to stabilize test conditions as much as possible. Patrol inspection of operating equipment and system shall be strengthened.

9.3.6

No irrelevant persons at test site. Guard line shall be in place for important rotating machines and test area.

9.3.7

During test, never allow operating the fan while exceeding rated current, maximum bearing temperature and maximum vibration.

10.

Appendix


Appendix 1 No.

REV A



Page 12 of 20

Commission Condition Checklist Items

Requirements

Result

1

Cold modelling calculation

Fulfilled

□Yes □No

2

Installation and angle inspection of burner nozzle

Fulfilled

□Yes □No

3

Test platform and lighting inside and outside the boiler

Erection fulfilled, accepted and eligible

□Yes □No

4

Measuring point installation

Fulfilled

□Yes □No

5

Trial operation of individual fan

Fulfilled and eligible

□Yes □No

6

Damper

Installation fulfilled and eligible upon commissioning

□Yes □No

7

Air pressure test

Test fulfilled and insulation over

□Yes □No

8

Metering elements such as pressure, temperature, etc.

Installation fulfilled and calibration accurate

□Yes □No

9

Cleanup of boiler inside and flue-gas and air system

Clean, without foreign matter

□Yes □No

10

Field condition

Clear road, sufficiency of illumination

□Yes □No

11


Usable

□Yes □No

12

Fire apparatus

Sufficient, convenient for use

□Yes □No

13

Commissioning tools and instruments

Prepared

□Yes □No

Commissioning Contractor Contractor: Owner:

Date: Date:

Date:


Date:

Verified by

Remar ks

Date:


REV A



Page 13 of 20

Appendix 2 Furnace speed measurement record list Furnace speed measurement record list Time Position

Side A

Elevation (mm)

1


2

Date:

Date:

Side B 3

4

2


Date:

1

Date:

3

4

Date:


Appendix 3

REV A



Page 14 of 20

Burner nozzle speed measurement record list Burner nozzle speed measurement record list

Time Name of Burner

Case 1

Case 2

Case 3

Remarks

A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4


Date:

Date:


Date:

Date:

Date:

Appendix 2

Record list of leveling test data for primary air coal pulverized pipe No.

Coal mill A

Coal mill B

Coal mill C

Coal mill D

Coal mill E

Measuring point 1 (in/out)

Owner:



#1 primary air duct #2primary air duct #3primary air duct #4primary air duct #1 primary air duct #2primary air duct #3primary air duct #4primary air duct #1 primary air duct #2 primary air duct #3 primary air duct #4 primary air duct #1 primary air duct #2 primary air duct #3 primary air duct #4 primary air duct #1 primary air duct #2 primary air duct #3 primary air duct #4 primary air duct

Commissioning Contractor Contractor:


Date:

Date:


Date:

Date:

Date:



Confir med by

Remark s

Appendix 3 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Record list of test parameter for aerodynamic field Item

Furnace draft Temp of flue gas Fixed blade opening of forced draft fan (A/B) Current of forced draft fan (A/B) Outlet pressure of forced draft fan (A/B) Differential pressure of forced draft fan (A/B) Bearing vibration of forced draft fan (A/B) Inlet air temperature of secondary air box side Secondary air temperature of air preheater outlet (A/B) Secondary air temperature of air preheater inlet (A/B) Bearing temperature of forced draft fan (A/B) Secondary air pressure of air preheater outlet (A/B) Secondary air differential pressure of air preheater inlet/outlet Differential pressure for furnace/ secondary air box side A Differential pressure for furnace/ secondary air box side B Air pressure at secondary air box side Air volume 1 at secondary air box side Inlet air temperature at secondary air box side Air volume 2 at secondary air box side Air temperature at forced draft fan inlet (A/B) Air temperature at forced draft fan outlet (A/B) Motor bearing temperature of forced draft fan (A/B) Motor coil temperature of forced draft fan (A/B) Guide vane opening of primary air fan (A/B) Current of primary air fan (A/B)

Unit

Case 1

Case 2

Case 3

Case 4

Confirmed by:

Remarks

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

Outlet pressure of primary air fan (A/B) Differential pressure of primary air fan (A/B) Bearing vibration of primary air fan (A/B) Primary air temperature at air preheater outlet (A/B) Primary air temperature at air preheater outlet (A/B) Bearing temperature of primary air fan (A/B) Primary air pressure at air preheater outlet (A/B) Primary air differential pressure at air preheater inlet/outlet Air temperature at primary air fan inlet (A/B) Air temperature at primary air fan outlet (A/B) Motor bearing temperature of primary air fan (A/B) Motor winding temperature of primary air fan (A/B) Movable blade opening of induced draft fan A Movable blade opening of induced draft fan B Current of induced draft fan A Current of induced draft fan B Inlet pressure of induced draft fan A Inlet pressure of induced draft fan B Inlet/outlet differential pressure of induced draft fan A Inlet/outlet differential pressure of induced draft fan B Bearing vibration of induced draft fan A Bearing vibration of induced draft fan B Bearing temperature of induced draft fan A Bearing temperature of induced draft fan B Motor bearing temperature of induced draft fan A Motor bearing temperature of induced draft fan B Primary air volume of coal mill A Inlet air pressure of coal mill A Outlet/Inlet differential pressure of coal mill A

55 56 57 58 59 60 61 62 63 64 65 66

Primary air volume of coal mill B Inlet air pressure of coal mill B Outlet/Inlet differential pressure of coal mill B Primary air volume of coal mill C Inlet air pressure of coal mill C Outlet/Inlet differential pressure of coal mill C Primary air volume of coal mill D Inlet air pressure of coal mill D Outlet/Inlet differential pressure of coal mill D Primary air volume of coal mill E Inlet air pressure of coal mill E Outlet/Inlet differential pressure of coal mill E


Date: Date:

Date:


Date:

Date:

Appendix 4

Erection drawing of scaffolding platform for aerodynamic field in boiler

See following for attached figure: Burner 燃烧器

23100

19600

网格铁丝 Grid wire

18100

Scaffold step 脚手架踏板

Grid 网格截面 section

拉线螺母 Stay nut

脚手架踏板 Scaffold step 12600

Burner燃烧器喷口 nozzle 1000mm 100mm

网格铁丝 Grid wire

150mm gap between steps at this point 此处踏板间隙150mm Manhole 人孔

Coordinat e坐标灯 lamp 600×1000mm

Coordinate lamp 坐标灯脚手架 Scaffold

Scaffold step 脚手架踏板

Description of erection of scaffold in boiler (for cold state aerodynamic field test) 1）

At the section 1.5m below lower primary air nozzle and the section of burner isolated area, the gang board shall be provided along the periphery of furnace; in addition, cross type gang boards shall be set up at the lower layer section along furnace center, and platform and climbing gang board shall be set up at 12.6m manhole, up to upper layer scaffolding platform. Please refer to schematic drawings. All platform gang boards shall be mounted with guardrail at the outer side. The width of gang board shall be 1m;

2）

At the manhole section after horizontal flue final stage reheater at furnace exit, two layers furnace-through gang boards shall be set up, and at the section of windward side, it shall be provided with three layers of soldering iron wires (connected through nuts). Please refer to schematic drawings. All platform gang boards shall be mounted with guardrail at the outer side.

3）

At the manhole section after horizontal flue final stage reheater at furnace exit, gang boards shall be set up and introduced to middle of flue; in addition, in-boiler camera platform shall be set up at platen superheater in the middle of furnace. The platform shall be about 1.5m wide and gang board shall be set up safely and securely; in addition, it requires that about 150mm gap shall be reserved in the middle, for the purpose of video recording. All platform gang boards shall be mounted with guardrail at the outer side.

4）

Scaffolds shall be set up nearby corner burners at windward side. The scaffolds shall be positioned in such ways, thus to be suitable for climbing of test personnel and not to block burner nozzle. The inner section of scaffolds shall be 600×1000mm. The distance from edge to nozzle shall be 1000mm. Please refer to schematic drawings.

5）

Four nuts (or iron hooks) shall be welded at furnace-surrounding water-cooling wall center at lower primary air nozzle section, for connecting the iron grid. In addition, the iron wire shall be connected at the place of 100mm from water-cooling wall, for measuring air speed against the wall. Please refer to schematic drawings.

6）

Please refer to schematic drawings for mounting of coordinate lamp. The coordinate lamp shall be applied with portable lamp and fixed with ＃8 iron wires, to prevent from blowing away by strong wind.



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-G-01-H-001 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI

CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY SiChuan Electric Power Commissioning & Test Institute Approval Review

Check Design

Date

Scale


DETAIL DESIGN STAGE

Procedure of Energy Source and Resource Economizing N/A

DWG No.


REV

A


Procedure of Energy Source and Resource Economizing

REV A


Page 2 of 8

Table of Contents

1

PURPOSE ......................................................................................................................................................... 3

2.

SCOPE .............................................................................................................................................................. 3

3.

PREPARATION BASIS .................................................................................................................................. 3

4.

BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT ........................................................................ 3

5.

TOOLS AND INSTRUMENT FOR COMMISSIONING............................................................................ 4

6.

MEASURES FOR COMMISSIONING ORGANIZATION ........................................................................ 4

7.

TECHNICAL MEASURES............................................................................................................................. 5

8

DIVISION OF STAGES AND OIL CONSUMPTION CRITERIA............................................................. 7

9.

OIL CONSUMPTION CRITERIA AND NOTES......................................................................................... 7

10. VERIFICATION OF ACTUAL FUEL OIL CONSUMPTION.................................................................... 7 11. SAFETY MEASURES..................................................................................................................................... 7

11.1

Safety rules for commissioning .......................................................................... 8

11.2

Personal Risk and Preventative Measures.......................................................... 8

11.3

Equipment Risk and Preventative Measures ...................................................... 8



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Page 3 of 8

1

Purpose

1.1

To save strategic energy sources of the country and reduce the investment in the project.

1.2

To examine the unit design level, manufacture and installation quality, commissioning plans, organization and management levels, and plant operators’ skill indirectly

1.3

To promote the cost-saving awareness of the employees of all associated parties.

2.

Scope This Procedure is a scheme for energy source and resource saving. The scope of commissioning associated with this scheme include four stages, namely boiler pickling, ignition and pipe blowing, unit synchronization with power grids, load operation and 30day reliability trial run.

3.

Preparation Basis

3.1

Startup and commissioning plans for PLTU 1 Jatim-Pacitan (2×315MW) Power Plant

3.2

Instruction manuals for combustion equipments of the boilers;

3.3

Boiler operation manual

4.


4.1

Two sets of natural circulation drum boilers with subcritical parameter and four corner tangential firing are provided in this project. It has single furnace with half open arrangement of II Type, brown coal fired, single reheating, balanced ventilation, solid slag removing, all steel structure and with metal rain shed on furnace top. All these three boilers are designed and manufactured by Dongfang Boiler Group Co,. Ltd. Boiler model: DG1025/17.4-II13. The firing mode in furnace is a positive, direct blowing, four-corner tangential firing with swing of burner nozzles. For the steam temperature of super heated steam, the water spray temperature reducer with I,II and III steps is provided for the adjustment of temperature and the arrangement of three steps and five points is provided. The swinging burner nozzle is used as the main way to adjust the steam temperature of the reheated steam, reducing temperature with water spray as auxiliary and spray temperature reducers are provided as well.

4.2

Main Parameters of Boiler (Design type of coal）

Unit

BMCR condition

ECR condition

work pressure of boiler drum flow of superheated steam

MPa t/h

18.77 1025

18.58 976.2

outlet pressure of superheated steam

MPa

17.4

17．32

℃

541

541

t/h MPa

839.4 3.76/3.58

802 3.59/3.41

inlet/outlet temperature of reheated steam

℃

329/541

324/541

Temp. of feed water

℃

281

278

Item

outlet temperature of superheated steam flow of reheated steam inlet/outlet pressure of reheated steam


4.3


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Temp of flue gas

℃

131

131

Outlet flue gas temp. of furnace

℃

985

994

Inlet air temp. of APH

℃

30

30

Outlet air temp. of APH

℃

359/351

359/351

calculated consumption of boiler fuel calculated efficiency of boiler

t/h %

161.58 93.26

154.23 93.71

Swing burners are adopted as burners which are arranged in four corners and double tangential firing is formed in the furnace and the presumed tangential are ф548mm and ф1032mm respectively. The horizontal bias burning technique in the design of pulverized coal nozzles is used to strengthen the stability of combustion in boiler when running with low load. Feature Data of Burner (design coal type/BMCR load） No.

Item

1 2 3

Primary air Secondary air Surrounding air Furnace air leakage

4

Air-to Coal Ratio (%)

Air Flowrate （m/s） 28 45 35

Air Temperature (℃) 65 346 346

Resistance (Pa) 1900 1000 ——

Details will be given after providing the instruction.

5.


5.1

Walkie talkie；

5.2

Fuel oil meters

6.


6.1

6.2


`Preparation and revision of commissioning procedures;

◆

`Preparation of commissioning plan;

◆

`Preparation of instruments and equipment required for commissioning；

◆

`Hold technical clarification meeting for commissioning;

◆

`Organize the commissioning work to be carried out by various parties;

◆

`Give instructions to operators in the operation;

◆

`Prepare commissioning report.

Responsibilities of Installation Contractor


6.3

6.5

6.6

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◆


◆


◆


◆


◆

Be responsible for temporary coordination of local control and instruments and connection terminals.


6.4





◆


◆


◆


◆




◆


◆


◆




◆


◆


7.

Technical Measures

7.1

The oil for commissioning shall be saved based on the condition that personal and equipment safety can be guaranteed and commissioning quality specified for each commissioning stage can be assured.

7.2

The fuel oil meters (flow meters) have been adjusted and calibrated and ready for use prior to ignition and confirmed by all associated parties. The initial values of these meters shall be



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recorded. 7.3

The fuel oil systems shall be purged with steam and oil circulation shall be performed 96 hours before ignition. It is allowed to ignite burners only after confirming that the filter screens are clean, in order to prevent oil guns from being clogged and poor atomization.

7.4

Pay special attention to cold-state inspection and preventative test activities in order to identify and eliminate any possible problem and defects regard to the design, construction and equipments, minimize the number of boiler shutdown during commissioning and therefore save fuel oil.

7.5

Carefully carry out inspection for damper baffle of boiler, flue air & air duct cleaning and inspection, cold-state air test, oil nozzle inspection, cold-state burner inspection, cold-state steam &water valve inspection, cold-state inspection and test for ST and boiler protection and cold-state startup test and inspection for pulverizing plants.

7.6

Ensure that feedwater quality conforms to the design requirements, carefully flush boiler and feedwater piping and ignite burners only after the boiler water quality is acceptable, and minimize the blowdown rate.

7.7

Commission the deaerators in advance to increase feedwater temperature and reduce fuel oil consumption.

7.8

Test the regulation characteristics of feedwater and desuperheating water regulating valves at cold state to ensure that the relevant automatic systems can be put into operation as soon as possible and fuel oil can be saved.

7.9

`During commissioning, the design coal shall be fired and industrial analysis of boiler coal shall be carried out on a daily basis. One copy of coal quality analysis report shall be submitted to the commissioning team on a daily basis.

7.10

The HP and LP heaters shall be put into operation as soon as possible. The oil consumption for stable combustion shall be reduced as possible after two sets of pulverizing plants are put into operation.

7.11

Oil guns shall be used in effective and reasonable manner according to actual operating conditions of the units and plans, the number of oil guns in use shall be increased or decreased on a timely basis and only necessary number of oil guns shall be put into operation.

7.12

Operators shall adjust combustion on a timely basis, raise furnace temperature as soon as possible. Operators shall cut off fuel oil supply and allow the units to operate fully on coal after the boiler load reaches 70% rated load (temporarily determined), boilers attain stable combustion and fire protective measures have been taken.

7.13

After the boilers start up, open drain valves as soon as possible and warm up piping to speed up warming prior to steaming to turbines. During hot startup, adjust the HP&LP bypass valve opening on a timely basis to increase steam temperature, drive steam turbines as soon as possible and save fuel oil.

7.14

Before the steam turbines are driven, prepare for electrical startup test. The tests shall be instructed on a unified basis to ensure safety. If no major problem affecting unit load increase exists after the units are connected with power grid and overspeed test has been conducted, allow the unit to operate under large load according to the load curve in order to exhibit any possible defect and prepare for 30 day trial run stage.

7.15

The operators of turbines, boilers, electrical, chemical, I&C, fuel and handling systems shall obey the uniform instruction, communicate with each other from time to time, and do well in various preparatory works to prevent time delay and unnecessary fuel oil consumption.

7.16

The leaders shall provide proper instruction and shift supervisors shall arrange for water, coal,



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electric power, oil, steam and chemical product supply and dispatching and communication works, and prepare for the test in all regards in order that the trial run activities can be carried out smoothly and continuously and boilers don’t consume fuel oil unnecessarily. 7.18

All professionals shall carefully operate, adjust and maintain equipments, prevent accident, damage to equipments and boiler and unit shutdown, and minimize the number of startup, otherwise, the project will be delayed and fuel oil will be consumed unnecessarily.

7.19

The maintenance personnel shall make all preparation and tools, materials and persons must be in place. Any abnormal condition must be repaired and inspected, and safety measures shall be in place and maintenance time shall be shorted to reduce oil consumption. In case a major equipment accident occurs and it is impossible to repair such trouble within a short time and carry out other commissioning activities, the boilers shall be shut down immediately.

7.20

In order to save fuel oil, an employee shall be assigned to calculate oil consummation at various stages and report to the trial run leading team.

8

Division of Stages and Oil Consumption Criteria

9.

Commissioning stage

Oil Consumption Planned (T)

Ignition and piping blowing

3000

Connection with power grid and operation under load

2000

30-day reliability test

1500

Total

6500

Oil Consumption Criteria and Notes The oil consumption criterion of Unit 1 is 6,500 tons calculated from initial ignition and piping blowing to the completion of 30 day reliability trial operation.

10.

Verification of Actual Fuel Oil Consumption

10.1

Strictly verify and record the amount of oil supply to the oil depot

10.2

Record oil level in the depot per 2 hours when the boilers consume fuel oil, per shift when the boiler does not use fuel oil. When oil is made up to the depot, the makeup amount and time shall be recorded and the signature of the persons accepting fuel oil shall be available.

10.3

During boiler operation, operators shall record oil level difference and makeup amount of the depot per shift and record the time when each oil gun is put into use.

10.4

The oil flow meters shall be used and initial reading of the meters and various operating values as well as the difference between oil supply and return amount shall be recorded. After the oil flow meter is used, the meter bypass valve shall be opened with the approval of the commissioning leading team.

10.5

The boiler commissioning personnel shall calculate and verify oil consumption according to the above information and report to the trial run leading team.

10.6

It is strictly prohibited to practice fraud.

10.7

Fuel oil consumption for use by the startup boilers shall not be considered.

11.

Safety Measures



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Page 8 of 8

11.1


11.1.1


11.1.2


11.1.3


11.2


11.2.1


11.3


11.3.1

Before fuel oil supply stops, the unit operation and boiler combustion shall remain stable.



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-G-01-H-002 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI


Check Design Scale


DETAIL DESIGN STAGE

Procedure of Boiler Integral Start-up N/A

DWG No.


REV

A


Procedure of Boiler Integral Start-up

REV A


Page 2 of 28


PURPOSE ............................................................................................................................................ 3

2.

SCOPE ................................................................................................................................................. 3

3.

PREPARATION BASIS....................................................................................................................... 3

4.

BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT ............................................................... 3

5.

TOOLS AND INSTRUMENT FOR COMMISSIONING................................................................... 5

6.

PREREQUISITE FOR COMMISSIONING ....................................................................................... 5

7.

MEASURES FOR COMMISSIONING ORGANIZATION ............................................................... 8

8.

COMMISSIONING PROCEDURE .................................................................................................... 9

9.

SAFETY MEASURES ...................................................................................................................... 15

10.

9.1

Safety rules for commissioning ........................................................................ 15

9.2


9.3

Equipment Risk and Preventative Measures .................................................... 15 APPENDIX................................................................................................................................ 17

Appendix 1 Integral Startup Condition Checklist .......................................................... 18 Appendix 2 Boiler Commissioning Parameter Record .................................................. 22 Appendix 3 Commissioning Parameter Record for Pulverizing Plants ......................... 23 Appendix 4 Record for Boiler MFT (OFT) and Integral Interlock Test......................... 24


1.


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Page 3 of 28

Purpose The unit integral startup is one major process of unit commissioning which is associated with safety and quality of unit startup and project completion etc. Through it, various performances of the units may be evaluated on a comprehensive basis. In order to guide boiler integral startup and commissioning and ensure safe and normal unit operation, this procedure has been prepared. During boiler integral startup, the previously-made commissioning of various subsystems can be also examined.

2.

Scope This procedure is applicable to integral startup and commissioning. The following systems need be commissioned:

2.1

Main steam and reheat steam systems;

2.2

Feedwater and desuperheating water systems;

2.3

Water drain& drainage, vent and blowdown systems;

2.4

Fuel oil and ignition system;

2.5

Flue-gas and air system;

2.6

Pulverizing plant;

2.7

Air preheater system;

2.8

Ash blowing systems

2.9

Furnace flame monitor system;

2.9

Other systems.

3.

Preparation Basis

3.1

Startup and commissioning plans for PLTU 1 Jatim-Pacitan (2×315MW) Power Plant

3.2

Engineering documents associated with PLTU 1 Jatim-Pacitan (2×315MW) Power Plant. (1)

Thermal system diagram provided by the design institute;

(2)

Pulverizing plant diagram provided by the design institute;

(3)


(4)

Boiler erection manual;

(5)

Boiler operation manual;

(6)

Manual of combustion equipment.

4.


4.1

Two sets of natural circulation drum boilers with subcritical parameter and four-corner tangential firing are provided in this project. It has single furnace with half open arrangement of II Type, brown coal fired, single reheating, balanced ventilation, solid slag removing, all steel structure and with metal rain shed on furnace top. All these two boilers are designed and manufactured by Dongfang Boiler Group Co,. Ltd. Boiler model：DG1025/17.4-II13.The firing mode in furnace is a positive, direct blowing, four corner tangential firing with swing of burner nozzles. Superheated steam temperature is adjusted by Stage 1, 2 and 3 spray type



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Page 4 of 28

desuperheaters. Three stages and five points are arranged in total. The swinging of burner nozzle is used as the main way to adjust the steam temperature of the reheated steam, reducing temperature with water spray as auxiliary and spray temperature reducers are provided as well. 4.2

Main Parameters of Boiler (Design type of coal) 单位 Unit

BMCR BMCR

BRL BRL

flow of superheated steam

t/h

1025

959.2

Superheated steam pressure

MPa

17.40

17.26

Superheated steam temperature

℃

541

541

Temp. of feed water

℃

280

275

flow of reheated steam

t/h

841

785.7

(inlet/outlet)

MPa

3．80/3.63

3.55/3.39

(inlet/outlet)

℃

330/541

322/541

Drum pressure

MPa

18.77

18.42

Desuperheating water flow at stage 1 desuperheater

t/h

19.41

27.03

Desuperheating water flow at stage 2 desuperheater

t/h

4.85

6.76

Reheater water spray flow

t/h

6.54

4.66


℃

987

989

Flue gas temperature at HP reheater outlet

℃

806

806

Flue gas temperature at HP superheater outlet

℃

732

731

Flue gas temperature at LP superheater outlet

℃

438

438

Flue gas temperature at economizer outlet

℃

388

387

Exhaust gas temperature (corrected)

℃

134

136

Air preheater inlet temperature

℃

30

30

Air preheater outlet temperature (primary /secondary)

℃

363/355

364/356

Fuel consumption

t/h

163.91

155.28

Boiler efficiency

%

93.04

92.94

Description

4.3

Swing burners are adopted as burners which are arranged in four corners and double tangential firing is formed in the furnace and the presumed tangential are ф548mm and ф1032mm respectively. The horizontal bias burning technique in the design of pulverized coal nozzles is used to strengthen the stability of combustion in boiler when running with low load.



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Feature Data of Burner (design coal type/BMCR load) No.

4.4

Item

Air-to coal Ratio (%)

Air Flowrate (m/s)

Air Temperature (℃)

Resistance (Pa)

1

primary airc

--

28

65

1900

2

secondary air

--

45

346

1000

3

Surrounding air

--

35

346

--

4

Furnace air leakage

--

--

--

--

Features of Fuel as below：

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 (1) (2) (3)

Item Carbon content as received basis As-received basis hydorgen As-received basis oxygen As-received basis nitrogen As-received basis sulfer As received basis ash content As received basis total moisture Water content as air dried basis Dry ash-free basis volatile component Fixed carbon content as received basis Low heat value as received basis Grindability coefficient Fineness of pulverized coal Ash fusing point Deformation temperature Softening temperature Fusion temperature

Symbol

Unit

煤种 DSG'D Coal type

Car

%

47.65

45.2

41.25～49.4

Har Oar Nar Sar Aar

% % % % %

3.36 14.49 0.77 0.23 3.5

3.15 11.7 0.70 0.25 4

3.375～4.55 7～16.25 0.375～0.975 0.1～0.23 3～6

Mar

%

30

35

25～35

Mad

%

20

25

15～25

Vdaf

%

50

46

42～67.8

FCar

%

30

--

28～42

Qnet,ar

KCal /kg

4200

3900

3900～4500

45 32

45

45-65

1150 1200 1300

1150 1200 1300

1150 1200 1300

HGI R90 DT ST FT

°C °C °C

5.


5.1

Walkie talkie;

5.2

Handheld vibration measurement instrument;

5.3

Digital multimeter;

5.4

Infrared themodetector.

6.

Prerequisite for Commissioning

Worst Coal Type

Range of Change in Coal Quality

Before formally beginning integral startup commissioning job, commissioning persons should conduct comprehensive checks on conditions that should be available for



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commissioning of this system according to contents listed in Annex 1 (Integral startup and Commissioning Condition Checklist) and make well the records. 6.1


6.1.1

Boiler proper: The installation and insulation works are complete. The hydrostatic test and air pressure test have been completed. Scaffolds, litter and foreign matters have been removed from furnace and flue gas& air ducts, all personnel have escaped and all manholes and access holes have been closed.

6.1.2

Flue gas and air systems: The installation and insulation works are complete. Commissioning of induced draft fans, forced draft fans, primary fans and air preheaters are complete.

6.1.3

Steam and water systems: the installation and insulation are complete, all supports and hangers are complete, pins have been removed from spring hangers and the entire systems have been checked and accepted. The blind plates for hydrostatic test have been removed.

6.1.4

Fuel oil systems: the installation and insulation are complete and trail run of various oil pumps have been successfully completed. The oil piping has been purged with steam.

6.1.5

Pulverizing plant: The installation and insulation works are complete. Static commissioning of coal mills and feeders are complete. Individual commissioning of coal mills and feeder and auxiliary facilities are complete.

6.1.6

Coal handling systems: the installation is complete and trail run of various auxiliary facilities have been successfully completed. Adequate design coal has been prepared and it is ready to feed coal to coal bunkers. The raw coal bunkers have been thoroughly cleaned.

6.1.7

Electrostatic precipitator systems: the installation and insulation are complete, voltage rising and rapping tests are finished and the entire systems have been checked and accepted. All electrostatic precipitators and economizer ash bunkers have been thoroughly cleaned and ready for operation.

6.1.8

Ash and cinder handling system: The installation and insulation works are complete. Individual trial run of various auxiliary facilities has been completed and the systems are ready for operation.

6.1.9

Flame scanning cooling air system: the installation is complete and flame scanning cooling fans have been commissioned.

6.1.10

Ash blowing systems; the installation and insulation are complete and the piping has been purged with steam. Static commissioning of all ash blowers has been successfully completed. The systems are ready for operation.

6.1.11

Auxiliary systems: the dosing, sampling, periodic blowdown, continuous blowdown, drain, vent, back-flushing and inert gas flushing systems have been installed and insulated.

6.1.12

Bottom steam heating system: the installation and insulation are complete and the systems are ready for operation.

6.1.13

Expansion systems: all expansion indicators have been installed as per the design and reset to zero point. All parties confirm that no expansion is restricted.

6.1.14

Fire protection system: Adequate fire fighting equipments are in place. Fire water (steam) systems are ready for use.

6.2

Conditions that must be available with electrical and I&C

6.2.1

Static commissioning of all motor-driven valves, pneumatic valves and dampers are complete and the valves and dampers are able to move freely under remote control.

6.2.2

Static commissioning of all alarm systems are complete and correct indication is given on all alarm windows.



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6.2.3

The emergency pushbuttons of all driving machineries are functional and wired correctly. Simulation operation indicates that they are in good order.

6.2.4

Commissioning of the PLC systems for auxiliaries is complete, the startup and shutdown logic of the PLC controllers are correct and the equipments can operate normally. （1） Startup condition of the oil lubrication stations of fans （2） Interlock relations of oil pumps; （3） Startup and shutdown conditions and interlock relations of induced draft fans, forced draft fans and primary fans （4） Interlock relations between dampers; （5） Program-based startup and shutdown test for all fans.

6.2.5

Static FSSS commissioning is complete. The interlock logic is correct and movement is reliable. （1） Furnace purging permissive; （2） MFT conditions and interlocked operation after MFT is active; （3） OFT conditions and interlocked operation after OFT is active; （4） Oil gun ignition permissive; （5） Oil gun startup and shutdown under program control; （6） Oil gun trip conditions; （7） Coal ignition permissive; （8） Coal mill& feeder startup permissive; （9） Coal mill startup and shutdown conditions.

6.2.6

Static commissioning of the data acquisition system is complete and the name and indication of all data points are correct.

6.2.7

Static commissioning of the industrial CCTV systems and flame scanning systems have been completed and they are ready for operation at any time.

6.2.8

Static commissioning of coal feeder weighing systems is complete and the systems are able to measure and indicate weights. .

6.2.9

Static commissioning and setting of furnace flue gas temperature probe is complete and the probe can move freely.

6.2.10

The static commissioning of ash blower and periodic blowdown PLCs has been successfully completed and simulation tests indicate that the relations are correct and movement is reliable.

6.2.11

The interlock and simulation tests have been performed upon turbines, boilers and generators. The test shows that the interlock is correct and operation is reliable.

6.3

Conditions that must be available with civil construction

6.3.1

The roads within the commissioning site must be free of obstructions. There is adequate lighting and reliable emergency illumination.



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6.3.2

Communication equipments at trial operation site are convenient and ready for use, and adequate fire fighting equipment and materials are provided.

6.4

Commissioning items which should be completed

6.4.1

The boiler proper has been pickled, the boiler front-end systems have been washed with alkaline and temporary systems have been removed.

6.4.2

The operation tests show that flue gas &air dampers, steam& water valves of boilers and dampers of pulverizing plants can move normally. The valves can move freely in correct direction and be fully closed and opened;

6.4.3

Boiler cold-state ventilation test is complete; Primary air leveling and flow calibration are complete.

6.4.4

The boiler piping has been blown. The temporary systems haven been removed.

6.4.5

The sequential control system (SCS) of boiler auxiliaries has been checked and tested;

6.4.6

The furnace safety supervision system (FSSS) has been checked and tested;

6.4.7

The emergency pushbuttons of various rotating machineries have been checked and tested.

6.4.8

All alarm signals have been checked and tested.

6.5

Other Necessary Conditions

6.5.1

The chemical water systems are functional and ready to supply conforming demineralized water.

6.5.2

The compressed air systems are functional and ready to supply conforming compressed air;.

6.5.3

The station service system is functional and able to supply power and cut off power supply according to the requirements.

6.5.4

The lighting and communication systems of the power plant are functional and ready for use at any time.

6.5.5

The central air conditioning system has been commissioned, functional and ready for use at any time.

7.


7.1



◆


◆


◆

Hold technical clarification meeting for commissioning;

◆


◆


◆


PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure 7.2

7.3

7.5

7.6

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◆


◆


◆


◆


Responsibilities of Equipment Manufacturer ◆

7.4





◆


◆


◆


◆




◆


◆


◆


Responsibilities of the Owner ◆


◆


◆


8.


8.1

Preparation Prior to Boiler Startup, and Ignition and Flushing Stage

8.1.1

Check and Confirmation of Flue Gas &Air Dampers and Steam &Water Valves Check and confirm that all flue gas &air dampers and steam &water valves are able to move freely in correct direction and fully opened and closed to their limit positions. The status indication is correct.



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For the Flue Gas & Air Damper Checklist, refer to the Fan Commissioning Procedures of the relevant rotating machineries. For the Steam & Water Valves Checklist, refer to the Piping Blowing Commissioning Procedures. 8.1.2

Cold ventilation test of boiler For primary air leveling and flow calibration, refer to Boiler Cold-state Ventilation Commissioning Procedure.

8.1.3

Check and Test of Interlock, Protection, Sequential Control and Alarm for Rotating Machineries Check and test of sequential control system (SCS) of boiler auxiliaries Check and operation test of emergency pushbuttons of various rotating machineries. All audible and visual alarm signals have been checked and tested. Refer to the Fan Commissioning Procedure of the relevant rotating machineries for details.

8.1.4

Check and Test of the FSSS (note: the interlock and protection test items shall be based on the result of logic discussion) Check and test furnace purging conditions; Check and test the result occurring after the MFT is active. Interlock test covering the turbine, boilers and electrical systems For details, refer to Appendix 4.

8.1.5

Boiler piping blowing. For details, refer to the Piping Blowing Commissioning Procedure.

8.1.6

Check and test of pulverizing plants. For details, refer to the Pulverizing Plant Startup and Commissioning Procedure.

8.1.7

Check and test of ash and cinder handling system. Refer to Commissioning Procedure for Ash and Cinder Handling System for detail.

8.1.8

Static Check and Commissioning of Ash Blower Systems Check the ash blower system piping, including expansion, supports and hangers. Check and confirmation of ash blowing system valves, and adjustment and test for ash blowing safety valves and pressure-reducing valves. Operational test of ash blowers (coordinate with I&C personnel and manufacturers) Simulation test of ash blower program control (coordinate with I&C personnel and manufacturers)

8.1.9

Check and test of flame scanning cooling air system and interlock test of two fans.

8.1.10

Simulation test of periodic blowdown program control (coordinate with I&C personnel)

8.2

Non-load Stage

8.2.1

Feed water to the boilers Water feeding mode of condensate transfer pumps (feed pumps): chemical demineralized water--- condensate make-up water tank--- condensate transfer pump (feed pumps) --feedwater piping--- economizer



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Water feeding mode of motor-driven feedwater pump: pump— feedwater bypass— economizer

Deaerator— motor-driven feedwater

Feedwater Flowrate Control:

Feedwater flow: 30 to 60 t/h;

Feeding duration: 2 to 4 hrs

The water feeding duration should be extended appropriately if the temperature difference between water and drum wall is above 50℃;

When the water level rises up to +200mm, stop feeding water, perform drum level protection test and ebsure the test result qualified. 8.2.2

Preparation for Ignition Put the boiler bottom steam heating system into operation Prior to ignition, the boiler bottom steam heating system shall be put into operation so that the boiler water and drum wall temperature is about 100℃ and the temperature difference between upper and lower wall is below 15℃, Slowly open the valves to supply steam to the lower steam headers. The heating rate shall not exceed 0.5℃/min and the steam supply flow shall be controlled properly so as to avoid excessive boiler proper vibration. Before ignition or pressure buildup, close and isolate boiler bottom heating steam source. Contact the relevant operators to start up electrical precipitator ash bunker and insulator heaters.

8.2.3

Boiler Lighting-up （1） Start up air preheater A and B. （2） Establish ventilation ducts and furnace bottom seal. （3） Start up induced draft fans and forced draft fan at Side A. （4） Start up induced draft fans and forced draft fan at Side B （5） Set furnace pressure to -100 to -200Pa （6） Start up one flame scanning cooling fan and put another fan into standby and interlock. （7） Adjust the boiler draft above 30% and purge furnace; （8） Perform fuel oil leak test; （9） Begin to time when purging begins again. After the purging is complete, MFT shall be reset automatically. After confirming that the ignition conditions are met, open the main oil valves and prepare for ignition. After the ignition order is issued, light up the boilers. When oil guns are put into operation, firstly start up the diagonally-arranged lower oil guns and oil gun changeover shall be carried out periodically. Startup and changeover of oil guns must take account of combustion conditions. Open the drains of superheated and reheated steam piping.



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Contact operators so that HP and LP bypass systems are put into operation Start up the steam ash blowing system of air preheaters and blow ash for air preheaters periodically. Continuously blow ash during initial ignition stage. 8.2.4

Raising Pressure After ignition, gradually start up oil guns according to cold-state temperature and pressure raising curve. During initial boiler startup, an appropriately-lower temperature and pressure raising rate may be employed. When the drum pressure increases to 0.098 to 1.0MPa, flush drum level meters, check water level and contact chemical operators to flush sampling lines. When the drum pressure increases to 0.172MPa, close all vent valves at boiler top. When the drum pressure increases to 0.4 to 0.5MPa, contact the installation contractor to tighten bolts and contact I&C operators to flush instrument piping. Close the drain valves according to steam temperature When the drum pressure increases to 1.0MPa, ask chemical operators to start up dosing system. At this time, the continuous blowdown systems may be put into operation. Start up periodical blowdown system according to the chemical requirements. Before the steam turbines attain stable speed, the furnace gas temperature probes shall be inserted continuously and the furnace outlet gas temperature shall not exceed 538℃

8.2.5

Turbine Rolling After steam temperature and pressure reach the parameters required for rolling, contact turbine operators to allow turbine to roll. The turbine rolling parameters shall be determined by turbine operators. After the turbine turns, ensure that the boiler parameters meet the requirements of turbine. When the turbine speed reaches 3000r/min, coordinate with electrical personnel to perform electrical tests and set boiler safety valves according to actual situations. After the electrical tests are completed, the unit shall be connected to grid and operate under load Furnace gas temperature probes may be withdrawn after steam is supplied boiler reheaters. The unit shall be disconnected with grid and overspeed test shall be performed after connection and operation with initial load for 4 to 6 hours. After the overspeed test is completed, the turbine may be shut down while the boiler continues to operate. The boiler safety valves shall be set.

8.3

Load Operation Stage

8.3.1

Ignition, turbine rolling, connection with grid and load operation shall be performed in the same way so as to remove silica deposits.

8.3.2

Prepare to start up pulverizing plants according to the unit load.

8.3.3

Start up two primary fans. The following conditions shall be met before the pulverizing system starts up: Drum pressure>3.5MPa； The air preheater outlet temperature shall be above 150℃.



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8.3.4

The manual desuperheating water valves shall be opened and desuperheating water shall be available before the pulverizing plant start up.

8.3.5

Warm coal mills and start up the first coal mill according to coal mill startup procedures. For coal mill startup procedures, refer to the Pulverizing Plant Commissioning Procedure.

8.3.6

When the coal feeding flow of the first set of pulverizing plant reaches 60 to 70 percent of rated value, the second set of pulverizing plant may be started up according to the load (about 60MW). Contact the Ash Control Room to put the Cinder system into operation.

8.3.7

When the coal feeding flow of the second set of pulverizing plant reaches 60 to 70 percent of rated value, the third set of pulverizing plant may be started up according to the load (about 120MW).

8.3.8

When the load reaches about 150MW, start up the second feedwater pump and allow two pumps to operate in parallel

8.3.9

When the load reaches 40 to 60%, coordinate with I&C personnel to enable AUTO mode. Automatic drum level control; Automatic furnace draft control; Automatic primary air pressure control; Automatic coal mill air flow control Automatic mill outlet temperature control; Automatic desuperheating water control.

8.3.10

After all oil guns stop, continuous ash blowing for air preheaters may stop. Contact the ash bunker operators to ensure that all electrostatic precipitators operate under electric field control. When the load exceeds 210MW, comprehensive ash blowing may be performed for boilers.

8.3.11

Start up the 4th coal mill and increase load.

8.3.12

When the load is about 70 to 80% and boiler attain steady combustion, perform the initial fuel oil cut-off test.

8.3.13

Coordinate with I&C personnel to enable AUTO mode. Automatic boiler combustion is ON; The CCS system is ON.

8.4

Full-Load Operation Stage Remove silica deposit when the boiler pressure is 25%, 50%, 75% and 100% rated value. 30-day trail run stage If necessary, shut down and maintain the units after the unit trial operation under load is completed. After then, start up the unit again, raise unit load to 315MW, and turn on the interlock, protection and instruments as well as the automatic control system of units. The units shall operate at full load state for at least 96hrs and operate under rated condition for 30 days to assess its reliability.

8.5

Hot Startup of Unit

8.5.1

Hot startup refers to startup which is carried out when the boiler is under pressure.

8.5.2

Prior to boiler hot startup, it is necessary to confirm that the maintenance works are complete.



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8.5.3

The procedures of boiler hot startup are basically similar to the one of cold startup.

8.5.4

Prior to ignition, all drain valves shall be closed.

8.5.5

During temperature and pressure rise, the boiler drain valves shall be controlled as follows: （1） After ignition, fully open the drain valves of superheaters and reheaters. （2） Open the drains upstream of the turbine MSVs and reheat steam piping drains to warm up piping, put HP and LP bypass systems and control temperature and pressure rise rate. （3） After the turbine turns, close the drains of superheaters and reheaters.

8.5.6

Turn on the furnace gas temperature probes to prevent boiler tube wall from overheating.

8.5.7

After ignition, put as many oil guns as possible into operation as soon as possible provided that the drum wall temperature difference does not exceed its limit. The purpose is to ensure that steam parameters reach the valves required for turbine rolling as soon as possible.

8.5.8

After the turbine rotates, close the drains at turbine side according to cylinder temperature.

8.5.9

Start up pulverizing plants according to the unit load requirements. Supply desuperheating water according to the temperature rise rate to prevent overheating.

8.6

Boiler Shutdown

8.6.1

Prior to shutdown, thoroughly check the systems and record defects.

8.6.2

Prior to shutdown, thoroughly blow ash from all heating surfaces.

8.6.3

How to Decrease Load from 315MW to 150MW. （1） The loading-down rate shall be 1%/min. （2） Change over main steam pressure control to MANUAL. （3） During loading-down, the coal feeders’ speed of operating pulverizing plants shall be reduced evenly and the primary air dampers of coal mills shall be operated evenly. When the coal feeder speed is reduced to about 30%, one set of pulverizing plants may be stopped. （4） When stopping coal feeders of pulverizing plants, the speed of operating coal feeders shall be appropriately increased according to turbine and load conditions. （5） Stop the 2nd set of pulverizing plant in the same way. （6） When the load is reduced to 200MW (TBD), put oil guns into use to support combustion. （7） When the load is reduced to 150MW, one motor-driven pump may be stopped, namely, only one pump is operating.

8.6.4

Inform the duty officer to stop electrostatic precipitator.

8.6.5

Continue to reduce load and use more oil guns to support combustion.

8.6.6

When the speed of coal feeders of rest pulverizing plants is reduced to 30%, one set of pulverizing plant may be stopped.

8.6.7

When the load is reduced to 30%, change over automatic feedwater from three-element control to single-element control.

8.6.8

Stop the final set of pulverizing plant and two primary air fans.



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8.6.9

Gradually stop oil guns according to loading-down situations.

8.6.10

Disconnect the generators from grids and stop turbines.

8.6.11

Boiler Shutdown

8.6.12

Stop forced draft fans and induced draft fans after purging at 30% MCR flow for 5 mins.

8.6.13

After boiler shutdown, raise drum level to the highest visual level, stop feedwater supply and open economizer recirculation.

8.6.14

Stop air preheaters if the conditions are met.

8.6.15

Stop flame scanning cooling fans if the conditions are met.

8.6.16

Put the boilers into hot standby or drain boilers depending on actual situations, and take measures to protect boilers against corrosion.

8.6.17

After boiler shutdown, continue to monitor exhaust gas temperature and air preheater outlet gas temperature to prevent air preheaters from catching fire.

8.6.18

After boiler shutdown, check that all oil guns are automatically purged and then withdrawn, and locally close manual valves of oil guns.

8.6.19

When the load and fuel supply are reduced during boiler shutdown, reduce air flow accordingly, pay attention to water level and steam temperature and change over from AUTO mode to MANUAL mode on a timely basis.

9.

Safety Measures

9.1


9.1.1

The parties participating in commissioning shall be familiar with and abide by the relevant safety rules, wear reasonable clothing and appropriate personal protective equipments。

9.1.2


9.1.3


9.1.4

Person from all specialties shall be on post in the whole process of test to ensure safe running of the equipment.

9.1.5

Startup and operation of the units shall be performed under unified order and the responsibility of each party shall be clearly determined

9.2


9.2.1


9.2.2

Commissioning personnel shall observe combustion state inside furnace properly to avoid scald.

9.3


9.3.1

Prior to unit startup, inspection and test works shall be strengthened and defects shall be identified and eliminated at cold state as possible. During startup, follow the temperature &



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pressure rising and loading-up curve and raise temperature, pressure and load for initial startup as slowly as possible. 9.3.2

During boiler startup, check thermal expansion at all parts from time to time. If abnormal expansion is found, stop raising temperature and pressure. Continue after problems are corrected.

9.3.3

When burners have been ignited and steam has not been supplied to reheaters, ensure that the furnace outlet gas temperature does not exceed 538℃, to protect reheaters

9.3.4

After turbines have started up, prevent sharp change in main and reheat steam temperature. Carry-over is strictly prohibited.

9.3.5

During boiler startup and operation, pay attention to whether automatic equipments operate correctly.

9.3.6

Pay attention to the change in air preheater outlet gas temperature and prevent reburning. If the flue gas temperature is found to be abnormal, start up ash blowers of air preheater immediately. At the initial stage of boiler startup, continuously blow ash till all oil guns stop.

9.3.7

Pay special attention to furnace draft change and combustion, especially when igniters and pulverizing plants are started or stopped, in order to maintain stable combustion.

9.3.8

Ensure that the exhaust gas temperature and oxygen content in flue gas are within the specified range and oxygen content in economizer outlet flue gas is about 4%.

9.3.9

Pay attention to furnace draft, air pressure, main steam pressure, water level, main steam temperature, reheat steam temperature controls and other automatic controls, and correct any problem immediately.

9.3.10

Pay attention to flame detectors, furnace flame CCTV display and observe, adjust and maintain stable combustion

9.3.11

Check that the furnace gas probes can be put into and out of use normally.

9.3.12

During startup and operation, observe superheater and reheater wall temperature to prevent overheating and tube burst.

9.3.13

When the load is below 50% MCR or combustion becomes unstable, put oil guns into use to support combustion and prevent furnace explosion.

9.3.14

During boiler operation, the fuel oil systems shall be ready for operation at any time. After the oil guns are out of use, they must be withdrawn from furnaces. Check oil guns per shift.

9.3.15

The pulverizing plants shall attain steady operation and supply coal having appropriate fineness and coal mill outlet temperature shall be within the set range. After pulverized coal is fed, pay attention to the change in steam temperature and pressure, load, and wall and flue gas temperature and prevent overtemperature and excessive steam temperature variation. When pulverized coal is initially fed, deslagging shall be strengthened (once per shift preferred) to prevent ash accumulation inside cold ash bunkers. After the ash handling systems attain normal operation, handle ash following the operation regulations.

9.3.16

After pulverized coal is fed, pay attention to the change in steam temperature and pressure, load, and wall and flue gas temperature and prevent overtemperature and excessive steam temperature variation. When pulverized coal is initially fed, deslagging shall be strengthened (once per shift preferred) to prevent ash accumulation inside cold ash bunkers. After the ash handling systems attain normal operation, handle ash following the operation regulations

9.3.17

During boiler startup and trial run, all interlock and protection systems shall be enabled according to the design. Disabling of a protection shall be approved by the commissioning leading team.



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9.3.18

During operation, pay close attention to bearing temperature, lube oil level and cooling water of rotating machineries. A problem, if found, shall be reported and corrected on a timely basis.

9.3.19

Check the operating conditions of equipments and systems from, time to time, at least twice per shift.

9.3.20

Safeguard the commissioning areas.

10.

Appendix



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Appendix 1 Integral Startup Condition Checklist No. 1.

(1)

(2)

(3)

(4)

(5)

(6)

Items

Requirements

Result

Mechanical system conditions

Boiler proper

Flue gas &air systems

Steam and water system:

Fuel oil system

Pulverizing plant

Coal handling system

The installation and insulation are complete

□Yes □No

The hydrostatic test and air pressure test have been completed.

□Yes □No

Scaffolds, litter and foreign matters have been removed from furnace and flue gas& air ducts, all personnel have escaped and all manholes and access holes have been closed.

□Yes □No


□Yes □No

Commissioning of induced draft fans, forced draft fans, primary fans and air preheaters are complete.

□Yes □No


□Yes □No

The systems are complete with all supports and hangers, and pins have been removed from spring hangers.

□Yes □No

The hydrostatic test is complete and blind plates have been removed.

□Yes □No


□Yes □No

Individual commissioning of all oil pumps has been successfully completed

□Yes □No

The oil piping has been successfully purged

□Yes □No


□Yes □No

Static commissioning of coal mills and feeders are complete.

□Yes □No

Individual commissioning of coal mills, feeder and auxiliary facilities are complete.

□Yes □No

Installation, individual commissioning of .all equipments and acceptance check are complete

□Yes □No

Ready to transfer coal to coal bunker at any time

□Yes □No

The raw coal bunkers have been thoroughly cleaned.

□Yes □No

Verified by

Remarks


(7)

(8)

(9)

(10)

Electrostatic precipitator system

Ash and cinder handling system Flame scanning cooling air system

Ash blowimg Systems


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□Yes □No

Voltage increase and rapping test are complete

□Yes □No

All electrostatic precipitators and economizer ash bunkers are thoroughly cleaned

□Yes □No


□Yes □No

Individual commissioning of auxiliary facilities are complete.

□Yes □No

The installation and individual commissioning of flame scanning cooling fans are complete

□Yes □No


□Yes □No

The piping has been purged with steam

□Yes □No

Static commissioning of all ash blowers has been successfully completed.

□Yes □No

Ready for operation

□Yes □No

□Yes □No

(11)

Auxiliary system

Auxiliary systems, such as the dosing, sampling, periodic and continuous blowdown, drain, vent, back flushing and inert gas flushing systems, have been installed and insulated.

(12)

Boiler bottom steam heating system

The systems have been installed and insulated and are ready for operation.

□Yes □No

(13)

Boiler expansion system;

All expansion indicators have been installed as per the design and reset to zero position.

□Yes □No

(14)

Fire protection system

Adequate fire fighting material are available and fire water systems have been installed and commissioned and ready for use

□Yes □No

(15)

Industrial water system;

The systems have been installed and commissioned and ready for use

□Yes □No

2

Electric, instrument and control condition

(1)

Motor-driven and pneumatic valves and dampers

The static commissioning is complete and valves and dampers can move freely in correct direction.

□Yes □No

(2)

Alarm systems

Static commissioning are complete and indication is correct

□Yes □No

(3)

Emergency pushbutton for

The pushbuttons are functional and wired correctly.

□Yes □No



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rotating machinery (4)

Auxiliaries PLC system

Commissioning is complete, startup and stop logic are correct and equipments can operate normally

□Yes □No

(5)

FSSS

The static commissioning is complete, logic is correct and movement is reliable

□Yes □No

Static commissioning is complete and the name and indication of all data points are correct.

□Yes □No

Static commissioning of the industrial CCTV systems and flame detector systems has been completed and they are ready for operation at any time.

□Yes □No

(7)

Automatic weighing system of coal feeders

Static commissioning is complete and the systems are able to measure and indicate coal weight accurately.

□Yes □No

(8)

Furnace gas temperature probe

Static commissioning and setting are complete and the probes can move freely.

□Yes □No

(9)

Program control of ash blowing and periodic blowdown

The static commissioning has been successfully completed and simulation tests indicate that the relations are correct and movement is reliable.

□Yes □No

(10)

Combined interlock test covering the turbine, boilers and electrical systems

The simulation test is complete, logic is correct and movement is reliable

□Yes □No

3

Civil works

(1)

Road Lighting

Clear Adequate normal and emergency lighting facilities is available

□Yes □No

(2)

Fire apparatus

Adequate

□Yes □No

(3)

Communicatio n equipments

Easy to use, adequate fire fighting apparatus are available

□Yes □No

4

Commissioning items which should be completed

(1)

Boiler proper Temporary systems of boiler front-end

Has been pickled Has been washed with alkali The normal system configuration has been resumed

□Yes □No

(2)

Dampers of flue gas and air systems as well

Commissioning is complete

□Yes □No

(6)

Data acquisition and supervisory control system



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steam and water valves (3)

Cold-state ventilation

The leveling and air flow calibration are complete

□Yes □No

(4)

Boiler piping blowing. Temporary system

Fulfilled Have been removed

□Yes □No

(5)

Auxiliary sequential control

Have been checked and tested

□Yes □No

(6)

FSSS


□Yes □No

(7)

Emergency pushbutton for rotating machinery


□Yes □No

(8)

Alarm signal


□Yes □No

5

Other conditions

(1)

Chemical water system

In good order and ready to supply demineralized water as per the design

□Yes □No

(2)

Compressed air system

In good order and ready to supply compressed air as per the design

□Yes □No

(3)

Station service system

In good order and ready to supply power as required

□Yes □No

(4)

Lighting and communication system;

In good order and ready to communicate

□Yes □No

(5)

Central system

Have been commissioned and read for operation at any time

□Yes □No

A/C


Contractor:

Date:

Date:


Dongfang Electric:

Date:

Date:



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Appendix 2 Boiler Commissioning Parameter Record Time

Condition

Description

Unit

Description

Unit

Unit load

MW

A APH outlet primary air temp

℃

Main steam flow

T/h

B APH outlet primary air temp

℃

Main steam pressure

MPa

Furnace draft

PA

Main steam temp

℃

Oxygen concentration at furnace outlet

%

Drum pressure

MPa

Oxygen content at air preheater outlet

%

Drum level

mm

Flue gas temperature at air preheater A inlet

℃

Feed water flow

T/h

Flue gas temperature at air preheater A outlet

℃

Feed water press

MPa

Flue gas temperature at air preheater B inlet

℃

Temp. of feed water

℃

Flue gas temperature at air preheater B outlet

℃

st

Data

1 stage desuperheating water flow

T/h


℃

2nd stage desuperheating water flow

T/h

Flue gas temperature at economizer inlet

℃

3rd stage desuperheating water flow

T/h

Temp. of flue gas

℃

A FD fan current

A

Reheat steam flow

T/h

B FD fan current

A

Reheat steam inlet pressure:

Opening of stationary blade of induced draft fan A

%

Reheat steam outlet pressure:

MPa

Opening of stationary blade of induced draft fan B

%

Reheat steam inlet temperature

℃

Air pressure at induced draft fan A inlet

KPa

Reheat steam outlet temperature

℃

Air pressure at induced draft fan B inlet

KPa

Reheater emergency water spray flow

T/h

A FD fan current

A

Reheater micro water spray flow

T/h ℃

B FD fan current

A

Ceiling superheater wall temperature

A FD fan dynamic blade opening

%

Wall enclosure superheater

wall temperature

℃

B FD fan dynamic blade opening

%

Low-temperature superheater wall temperature

℃

A FD fan outlet air press

KPa

Platen

℃

B FD fan outlet air press

KPa

Rear platen

A APH outlet secondary air temp

℃

High-temperature superheater wall temperature

℃

B APH outlet secondary air temp

℃

Platen

reheater wall temperature

℃

Secondary air tank pressure at Side A

KPa

High-temperature reheater wall temperature

℃

Secondary air tank pressure at Side B

KPa

Burner angle of swing

%

Primary air fan A current

A

B primary fan current

A

IGV opening of primary air fan A

%

IGV opening of primary air fan B

%

Air pressure at primary air fan A outlet

KPa

Air pressure at primary air fan B outlet

KPa


Date:

Date:

superheater

wall temperature

superheater

wall temperature


Dongfang Electric:

Date:

Data

℃

Date:



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Appendix 3 Commissioning Parameter Record for Pulverizing Plants Time

Condition

Description

Unit

Coal mill current

A

Coal feeding flow

t/h

Primary air flow entering mill

t/h

Mill inlet pressure

KPa

Mill outlet pressure

KPa

Differential pressure across coal mill

KPa

Differential pressure across mill grinding disc

KPa

Temperature of coal pulverizer motor bearing

℃

Temperature of mill motor stator winding

℃

Air temperature at coal mill inlet

℃

Outlet temperature of coal pulverizer is >55℃

℃

Differential pressure across mill grinding roll

KPa

A

B

C

D

Commissioning Company:

`Date:

`Operation Company：

`Date:

Construction Contractor：

`Date:

`DEC：

`Date:

E



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Appendix 4 Record for Boiler MFT (OFT) and Integral Interlock Test No. 1. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) 2.

Test item Furnace purging permissive No MFT trip conditions No flame is detected by a flame detector Any forced draft fan operating Any induced draft fan is running The furnace pressure is normal (from the MCS) No emergency boiler stop pushbutton pressed Fuel oil return mains shutoff valve closed Fuel oil mains quick-closing valve closed All the oil valves closed All coal mill stopped Al primary air fans stopped All coal feeders stopped Both air preheater are operating Swinging burners at horizontal position Air flow entering furnace (from the MCS) higher than 30% BMCR Air flow entering furnace (from the MCS) lower than 40% BMCR All secondary air dampers are at PURGING position Furnace pressure normal Flame detector cooling air pressure normal Normal drum level (two-out –of three) Check MFT condition

Fixed value

Results

Remarks


(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

(13)

(14)


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Control power failure: Power supply to the FSSS cabinet fail Two forced draft fans stop Two induced draft fans stop Manual MFT Drum level above +250mm (two-out of-three, at least 2s) Drum level below -250mm (two-out of-three, at least 2s) High furnace draft (2 out of 3), set value +1960Pa without time delay Low furnace draft (2 out of 3), set value -1960Pa without time delay Air flow entering furnace <30% for at least 60s a. Load >40%, steam turbine tripped When the load is below 40%, the turbine is tripped after 2s and the bypass is invalid (the HP bypass valve is closed or all of LP bypass is closed) Coal mills at any layer is running, all primary air fans stop and no oil layer is operating All air preheaters stop, 5s time delay Total flame loss (3s pulse). When 3/4 oil flame detectors do not detect flame and 3/4 coal flame detectors do not detect flame, it is considered that no flame is detected inside furnaces. When no flame is detected and burner operation is recorded, all flame loss is generated. That is to say, all flame loss is not assumed for a boiler not running. All furnace flameout (all flame loss) ¾ When only fuel oil is fired, total furnace flameout (3 out of 4 for each layer) ¾ When only coal is fired, total furnace flameout (3 out of 4 for each layer) ¾ When both oil and coal are fired, total furnace flameout All fuel loss (5 s pulse): when all oil valves are closed or quick-closing valves on oil mains are closed, and all coal feeders stop or all coal mills stop AND “Burner Operation” signal. All fuel loss ¾ When only oil is fired, angle oil valves are fully closed or quick-closing oil valves are closed ¾ When only coal is fired, fuel operation is recorded and all coal mills stop



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¾

(15) (16) (17) (18) (19) 3. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

When both oil and coal are fired, angle oil valves are fully closed or quick-closing oil valves are closed AND “ Fuel Operation” and all coal mill stop. Low flame scanning cooling air pressure, <5.5kPa (10s time delay, 2 out of 3) All flame scanning cooling fans stop All feedwater pumps stop Re-purge request (a short pulse is issued if no angle oil valve is opened within 60 min after purging is complete) Generator transformer protection is triggered Equipment interlocked with MFT audible and visual alarm are issued and furnace purging request is issued Trip all oil burners, close all oil valves, trip and withdraw oil guns, prohibit and withdraw ignition guns, disable oil gun purging and close all purge valves Close oil supply fast valve of oil manifold Close motor-driven valves on oil return mains Trip all coal pulverizers Trip all coal feeders Close all mill outlet air dampers; Close cold and hot air quick-closing valves as well as cold and hot air regulating valves of all coal mills. Trip all primary fans (including sealing air fans) Send MFT signal to the CCS, SCS and ETS systems etc. Change over two forced draft fans from AUTO to MANUAL, automatically reduce the opening to startup purging position (when the total air flow at purging position is above 30%) Change over two induced draft fans from AUTO to MANUAL, move the IGV to purging position to maintain a normal furnace pressure

¾ (13)

Furnace FSSS natural draft (when stopping of induced and forced draft fans causes MFT, the stationary and moving blade of fans will be fully opened and locked for 15min), all air dampers of burners will be fully opened after 1min and control will be changed over from AUTO to MANUAL.

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure ¾

(14) (15) (16) (17) (18) (19) (20) (21) (22) 4. (1) (2) (3) (4) (5) (6)


REV A


Page 27 of 28

Adjust air flow to the minimum purging flow (when the total flow at purging position is above 30%, the moving blade of forced draft fans will reach the purging position automatically, stationary blades of induced draft fans enter protection mode to maintain furnace pressure), all burner air dampers are fully opened and the control will be changed over from AUTO to MANUAL ¾ Maintain current air flow, all burner air dampers remain positions and fully opened after 5min, the control will be changed from AUTO to MANUAL and moving blades will be forced for 5min (when the total air flow is below 30%, the moving blades of blowers remain position and stationary blades of induced draft fans are under protection mode to automatically maintain furnace pressure) Trip MFT relay (fail-trip) Main and auxiliary desuperheating water valves of superheater systems are closed, all regulating valves are closed to zero position and the control is changed over from AUTO to MANUAL. Main and auxiliary desuperheating water valves of reheater systems are closed, all regulating valves are closed to zero position and the control is changed over from AUTO to MANUAL. Trip ash blowing systems: close the main motor-driven valve, and operating ash blowers need be out of service. Send MFT signal to the CCS, SCS and ETS systems Steam turbine tripped Generator transformer protection tripped The swinging mechanism of burners moving to horizontal position automatically Electrostatic precipitators tripped Logic check for FSSS hard-wired control circuit All primary air fans tripped All mills tripped All coal feeders tripped Fuel oil return electric valves closed Quick-closing fuel oil supply valves closed All angle oil valves of oil guns fully closed


(7) (8) (9) (10) (11) 5. (1) (2) (3) 6. (1) (2)


REV A


Page 28 of 28

The main electric desuperheating water valves of superheaters close The main electric desuperheating water valves of reheaters close Electrostatic precipitators tripped Ash blowing systems tripped ETS loss Combined interlock test covering the turbine, boilers and electrical systems When boiler MFT occurs, the ST and generator oil circuit-breakers shall be tripped When the ST is tripped and load is above 40%, the boiler MFT shall be triggered and generator oil circuit-breakers shall be tripped When the generator-transformers are tripped, the ST shall be tripped. When the ST is tripped and the load is above 40%, the boiler shall be tripped. MFT resetting condition (AND) Furnace purging finished No MFT trip conditions


Date:

Date:


Dongfang Electric:

Date:

Date:



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-M-01-HH-001 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI


Check Design

Date

Scale


DETAIL DESIGN STAGE

Procedure of Fuel Cutoff and Stabilizing

Burning N/A

DWG No.


REV

A

PLTU 1 Jatim-Pacitan（2×315MW） Project 调试程序 Commissioning Procedure

Procedure of Fuel Cutoff and Stabilizing Burning

REV A


Page 2 of 15


PURPOSE ............................................................................................................................................ 3

2.

SCOPE ................................................................................................................................................. 3

3.


4.

BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT ............................................................... 3

5.


6.

PREREQUISITE FOR COMMISSIONING ....................................................................................... 5

7.

MEASURES FOR COMMISSIONING ORGANIZATION ............................................................... 6

8.

COMMISSIONING PROCEDURE .................................................................................................... 7

9.

SAFETY MEASURES ........................................................................................................................ 9

10.

9.1

Safety rules for commissioning .......................................................................... 9

9.2

Personal Risk and Preventative Measures.......................................................... 9

9.3

9.3 Equipment Risk and Preventative Measures ................................................ 9 APPENDIX................................................................................................................................ 10

Appendix 1 Commissioning Condition Checklist.......................................................... 11 Appendix 2 Format for Trial Run Record ...................................................................... 12 Appendix 3 Test Coal Quality Record............................................................................ 14 Appendix 4 Pulverized Coal Fineness Record ............................................................... 15


1.


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Page 3 of 15

Purpose Stable combustion and safe fuel oil cut-off reached in the process of commissioning for boiler start-up with load can save fuel oil and increase economic operation of units.

2.

Scope This procedure is applicable to the commissioning of low load stable combustion after boiler fuel oil cut-off, including check and verification of boiler protection, combustion setting before fuel oil cut-off, fuel oil cut-off test and combustion setting after fuel oil cut-off.

3.

Preparation Basis

3.1

DRGs of flue-gas and air system and pulverized coal system;

3.2


3.3

Manual of combustion equipment;

3.4

Manual of coal mill.

4.


4.1

Two sets of natural circulation drum boilers with subcritical parameter and four corner tangential firing are provided in this project. It has single furnace with half open arrangement of II Type, brown coal fired, single reheating, balanced ventilation, solid slag removing, all steel structure and with metal rain shed on furnace top. All these three boilers are designed and manufactured by Dongfang Boiler Group Co,. Ltd. Boiler model: DG1025/17.4-II13. The firing mode in furnace is a positive, direct blowing, four-corner tangential firing with swing of burner nozzles. For the steam temperature of super heated steam, the water spray temperature reducer with I,II and III steps is provided for the adjustment of temperature and the arrangement of three steps and five points is provided. The swinging of burner nozzle is used as the main way to adjust the steam temperature of the reheated steam, reducing temperature with water spray as auxiliary and spray temperature reducers are provided as well。

4.2

Main Parameters of Boiler (Design type of coal）

Item

Unit

BMCR Condition

ECR condition

MPa

18.77

18.58

t/h

1025

976.2

Outlet pressure of superheated steam

MPa

17.4

17．32

Outlet temperature of super heated steam

℃

541

541

Flow of reheated steam

t/h

839.4

802

MPa

3.76/3.58

3.59/3.41

Work pressure of boiler drum Flow of superheated steam

Inlet/outlet temperature of reheated steam

PLTU 1 Jatim-Pacitan（2×315MW） Project 调试程序 Commissioning Procedure Inlet/outlet steam

4.3


REV A


Page 4 of 15

pressure

of

reheated

℃

329/541

324/541

Temp. of feed water

℃

281

278

Temp. of flue gas

℃

131

131


℃

985

994

Inlet air temp. of air PH

℃

30

30

Outlet air temp. of air PH

℃

359/351

359/351

Calculated consumption of boiler fuel

t/h

161.58

154.23

Calculated efficiency of boiler

%

93.26

93.71

Swing burners are adopted as burners which are arranged in four corners and double tangential firing is formed in the furnace and the presumed tangential are ф548mm and ф1032mm respectively. The horizontal bias burning technique in the design of pulverized coal nozzles is used to strengthen the stability of combustion in boiler when running with low load. Feature Data of Burner (design coal type/BMCR load） No.

4.4

Air-to coal Ratio (%)

Item

Air Flowrate (m/s)

Air Temperature (℃)

Resistance (Pa)

1

Primary air

28

65

1900

2

Secondary air

45

346

1000

3

Thrice air

3

Surrounding air

35

346

——

4

Furnace leakage

Verified coal type

air

Features of Fuel as below： No.

Item

Symbol

Unit

1 2 3 4 5

Carbon (as-received basis) Hydrogen (as-received basis) Oxygen (as-received basis) Nitrogen (as-received basis) Total sulphur (as-received basis) Ash content (as-received basis) Water content (as received basis) Water content as air dried basis Volatile matter (dry ash-free

Car Har Oar Nar

% % % %

Design coal type 47.65 3.36 13 0.77

Sar

%

0.23

Aar

%

5

Mar

%

30

Mad

%

20

Vdaf

%

54

6 7 8 9


10 11 12 13 14 4.5


REV A


Page 5 of 15

basis) Net calorific value Hardgrove grindability coefficient Ash deformation temperature Ash softening temperature Ash fusion temperature

Qnet.ar

Kcal/kg

HGI

4200 45

DT ST FT

℃ ℃ ℃

1150 1200 1300

Characteristics of Fuel Oil Items

Unit

Light Diesel Oil

Maximum ash content

%

Max. sulfur content

%

Max. water content (vol%)

%

Residue (wt %)

%

High heat value

kJ/kg

Density (15℃)

kg/m3

≥847

Kinematic viscosity (100℃)

Cst

≥1.0

Pour point

℃

Flash point (closed cup)

℃

≥50

Relevant Indian standards Details will be given after providing the instruction.

5.


5.1

Walkie talkie；

5.2

Vibration measurement instrument；

5.3

Infrared thermodetector.

6.

Prerequisite for Commissioning Before formally beginning commissioning job, commissioning persons should conduct comprehensive checks on conditions that should be available for commissioning of this system according to contents listed in Attachment 1 (Commissioning Condition Checklist) and make well the records.

6.1

Each function of FSSS must be tested prior to start-up of boiler to ensure its action is correct and reliable. All of its functions will be put into service step wise in the process of the trial run.

6.2

The main protection of boiler must be checked and verified again before fuel oil cut-off of boiler. For individual protection which is released because of fault or can not be put into service, approval by the command group of trial run is required for the execution and for the important one, and approval by the leadership group of trial run is required for important items.

6.3

The combustion in the furnace shall be observed and checked again prior to fuel oil cut-off of



REV A


Page 6 of 15

boiler to ensure that the firing is stable, flame is clear, there is no obvious coking or other abnormal situation. 6.4

The adjustment test for pulverization plant and firing in boiler has been completed and the plant runs normally before fuel oil cut-off test.

6.5

The hot-state adjustment of pulverizing plant is finished and the fineness of coal powder is up to the design requirement.

6.6

Confirm that coal quality conform to design requirements prior to fuel oil cut-off. During the test, the significant change in coal quality is not allowable and coal quality shall remain in the normal range.

6.7

Prior to the test, the boilers have operated for at least successive 12 hrs, the boilers have attain steady operation for at least 2 hrs under the test load, the units have attained steady operation, main parameters are normal and main and auxiliary equipments operate properly.

6.8

Before fuel oil cut-off, the related automation at boiler side shall be tried to put into service (for instance, feed water, desuperheating water auto, auto of ID, FD and primary fans and auto of main steam pressure).

6.9

A complete ash steam purging for boiler proper shall be conducted before fuel oil cut-off.

6.10

The possible accidents, such as fire out, water cut-off, turbine tripping and no auxiliary power supply, shall be considered properly before fuel oil cut-off.

6.11

HP heater shall be put into service in the test to ensure that the pressure prior to TG stable.

6.12

The measure points of temperature on up and down wall of boiler drum, temperature of SH tube wall and temperature of RH tube wall shall be checked for correctness of reading before the test.

6.13

The fire protection of boilers is put into normal operation and flame scanning signals are sensitive and reliable.

6.14

The hot air recirculation is put into operation to increase air preheater inlet air temperature and prevent low-temperature corrosion of air-preheaters.

6.15

The outlet damper of coal mill separator has been adjusted properly as per requirement of coal powder fineness before the test.

6.16

The adjustment of burners is free and its action is reliable.

6.17

Test instruments are available.

7.

Measures for Commissioning Organization This procedure shall be executed under the organization of commissioning contractor. The Contractors shall cooperate closely with each other according to their respective work responsibilities so as to guarantee safe and effective implementation of commissioning. The division of works is as follows:

7.1



◆


◆


◆



7.2

7.3

7.5

7.6

REV A


Page 7 of 15

◆


◆


◆




◆


◆


◆


◆



7.4





◆


◆


◆


◆




◆


◆


◆




◆


◆


8.


8.1

Time schedule and method for tests The test can be conducted at night when the unit peak load is controlled by the power grid as



REV A


Page 8 of 15

per arrangement in trial run plan. The test schedule will be submitted to dispatch center for approval before it is executed. It is requested, under permit able condition, that the operation of the mill corresponded to the lowest layer powder nozzle shall be kept by all means to maintain the lower flame center and firing stably in the purpose of ensuring the temperature of SH metal wall in the normal range and proper main and reheated steam temperature. 8.2

Test Procedures

8.2.1

During firing adjustment, the output of upper layer burners shall be reduced gradually with the decrease of electric load and the coal reduction shall be done slowly, firstly fast and then slow. Shut down the fourth pulverizing plant and close corresponding secondary air damper (or the lowest opening to cool the burner) when the load is reduced to 80%. If the burning is proper at this moment and coal flame scanned stable, the output of the third pulverizing plant can be reduced continuously. If the signal of flame scanning becomes weak in large extent or the fluctuation of negative pressure in the furnace increases, it shows that the firing stability in the furnace is affected. The load reduction shall be stopped when there is no improvement after adjustment. The load reduction can be continued when firing condition has been improved after corresponding firing adjustment. In addition, the outlet flue gas temperature of furnace shall be monitored for maintaining at relatively high level.

8.2.2

Shut down the third pulverizing plant when the load reduced to approximately 60% with the same method above. Close the corresponding secondary air damper after shutting down the mill.

8.2.3

Continue to reduce load and when the load is reduced to less than 60%, keep the first and second pulverizing plant working and the output will be reduced gradually with the change of load. First reduce the fuel volume of upper layer and then the lower layer. While reducing the fuel, the primary air of the pulverizing plant shall be adjusted properly to maintain proper speed of primary air, coal powder density and higher outlet temperature of coal mill. At the same time, the secondary air will be reduced properly to maintain rational content of oxygen and the air and coal ratio curve of coal mill shall be noted and the primary air volume shall be adjusted to maintain proper density of primary air and powder at spout of burners.

8.2.4

Stop load reduction when the load is reduced to 50% and there is obvious weakening of signal from flame scanner of A and B layers. The test can start when, from observation through local flame opening, flame in the furnace is stable and bright, firing point of flame nozzle is proper and the temperature at furnace outlet is not reducing any more and is basically stable.

8.2.5

Confirm operating condition after the boilers have attained steady operation for 1 hr.

8.2.6

After verification of work condition and firing stable, maintain running stably for 2 hrs at this load until the test is completed. All types of boiler protection shall be put into service in the process of test and for stable firing and facilitating the control; the primary air volume control of mill can be switched over to manual while all others will be put into service automatically.

8.2.7

The primary and secondary air volume of all burners will be controlled by auto adjustment. The auto can be released, if necessary, and conduct the adjustment manually.

8.2.8

During the test, the participant of test shall strengthen local firing observation and the operator shall strengthen monitoring parameters of flame scanning signal, negative pressure in furnace, volume of primary air, volume of secondary air, oxygen content, flue gas temperature, etc. If the fluctuations are great, the fuel reduction can be suspended and the test can be continued after the firing is adjusted to stable.

8.2.9

The speed of coal and load reduction in the test depends mainly on the change of firing intensity and stability and the maintenance of proper primary air volume, secondary air volume and oxygen content shall also be noted.

PLTU 1 Jatim-Pacitan（2×315MW） Project 调试程序 Commissioning Procedure 8.2.10


REV A


Page 9 of 15

Record and measurement of data in test Raw coal sampling and analysis shall be done every 1hour during the test.

9.

Safety Measures

9.1


9.1.1


9.1.2


9.1.3


9.1.4

Person from all specialties shall be on post in the whole process of test to ensure safe running of the equipment.

9.1.5

The process of fuel oil cut-off and load reduction shall be commanded on a uniform basis and operation shall be done carefully.

9.2


9.2.1

Flame observers shall communicate frequently with CCR operators. Flame observers shall use correct methods to avoid burns.

9.3

9.3 Equipment Risk and Preventative Measures

9.3.1

Suspend all other tests and important operation in the process of the test. If there is an important operation, suspend the test firstly.

9.3.2

In case unstable firing is observed in the process of fuel oil cut-off and load reduction, fuel oil shall be filled to assist firing. It shall be verified that the firing in the furnace is not extinguished before filling the fuel oil.

9.3.3

When the bad firing of individual burner is observed during the test, suspend load reduction and adjust firing. The load reduction and the test can only be continued until the firing is stable.

9.3.4

If it is found that the fluctuation of negative pressure in the furnace is greater, parameters of load, steam temperature and steam pressure are abnormal and flame cannot be seen on flame TV in the process of fuel oil cut-off and load reduction, firing extinguished can be determined. If MFT doesn't work at this moment, immediately operate MFT manually.

9.3.5

The operation person shall operate smoothly and slowly when reducing load in the process of the test.

9.3.6

Necessary pre-setting of important parameters, such as steam temperature, etc. shall be done properly when the coal mill is suspended.

9.3.7

When reducing primary air pressure and secondary air volume, reduce coal feed first and then reduce air volume. The operation shall be slow to avoid air amount fluctuating in large extent, resulting in disturbance of steam temperature, load, etc.

9.3.8

Boiler ash blowing or other work, which affecting firing in the boiler, shall be prohibited during the test.



REV A


Page 10 of 15

9.3.9

Gradually reduce boiler load with the margin of 3%~10% of rated load in the process of test and maintain for 15 to 30min under each step of load until the lowest load of stable firing is reached.

10.

Appendix



REV A


Page 11 of 15


Items

Requirements

Result

Verified by

1

Function test of FSSS system

Action correct and reliable

□Yes □No

2

Inspection and verification of main protection

Reliable

□Yes □No

3

Inspection of firing in furnace

firing stable and flame clear

□Yes □No

4

Pulverizing plant adjustment and combustion adjustment and test

Completed

□Yes □No

5

Pulverizing plant and fineness of pulverized coal

Operate normally, acceptable fineness

□Yes □No

6

Coal quality

Stable and meet requirements

□Yes □No

7

Unit operation prior to the test

Have operated continuously for at least 12 hrs Have operated for at least 2 hrs under the test load

□Yes □No

8

Automatic control at boiler side

Try best to put into service

□Yes □No

9

Ash steam blowing

Completed before fuel oil cut-off

□Yes □No

10

Presume of accident

Completed

□Yes □No

11


Commissioning is finished, can be put into operation

□Yes □No

12

HP heater system

Put into operation

□Yes □No

13

Temperature measure point

Reading correct and up to standard

□Yes □No

14

Fire extinguish protection and flame scanning signal

Protection put into service and signal reliable

□Yes □No

15

Burners

Adjustment free and action reliable

□Yes □No

16

Outlet damper for coal mill separator

Adjustment as per coal powder fineness completed

□Yes □No

17

Testing Instruments

Prepared

□Yes □No


Date: Date:

Date:


Dongfang Electric:

Date: Date:

Remar ks



REV A


Page 12 of 15

Appendix 2 Format for Trial Run Record

Time Unit load

Name

Unit MW

Main steam flow

T/H

Main steam pressure

MPa

Main steam temp.

℃

Drum pressure

MPa

Drum level

mm

Feed water flow

T/H

Feed water pressure

MPa

Temp. of feed water

℃

First step temp. reduction water flow, A Side First step temp. reduction water flow, B Side Second step temp. reduction water flow, A Side Second step temp. reduction water flow, B Side

℃ ℃ ℃

Reheat steam inlet pressure

MPa

T/h

Reheat steam outlet pressure

MPa

B IDF inlet air press

KPa

A FD fan current

A

B FD fan current

A

A FD fan outlet air pressure

℃

T/h

KPa

blade

℃

T/h

A IDF inlet air pressure

dynamic

℃

Flow of reheated steam

%

blade

%

T/h

A/B IDF static blade opening

dynamic

%

Temp. of flue gas

A

% % KPa

`

Unit Pa

T/h

A/B IDF current

A FD fan opening B FD fan opening

Data

Condition Name Furnace negative pressure Oxygen concentration at furnace outlet Oxygen content at air preheater outlet Flue gas temperature at air preheater A inlet Flue gas pressure at air preheater A outlet Flue gas temperature at air preheater B inlet Flue gas temperature at air preheater B outlet Outlet flue gas temp. of furnace Flue gas temperature at economizer inlet

Reheat steam inlet and outlet temperature Reheat desuperheating water flow at Side A/B Steam temperature upstream of Stage 1 desuperheating water Steam temperature downstream of Stage 1 desuperheating water Steam temperature upstream of Stage 2 desuperheating water Low-temperature superheater wall temperature Platen superheater wall temperature High-temperature superheater wall temperature Low-temperature reheater wall temperature

℃

℃ T/H ℃ ℃ ℃ ℃ ℃ ℃ ℃

Data



REV A


Page 13 of 15

B FD fan outlet air pressure A APH outlet secondary air temp. B APH outlet secondary air temp. A primary air fan guide blade opening B Secondary air fan guide blade opening A APH outlet primary air temp. Commissioning Contractor: Contractor: Date: Owner Date:

KPa

High-temperature reheater wall temperature

℃

℃

A Primary air fan current

A

℃

B primary air fan current

A

% % ℃ Date:

Air pressure at primary air fan A KPa outlet Air pressure at primary air fan B KPa outlet B APH outlet primary air temp ℃ Operation Contractor: Dongfang Electric:

Date: Date:



REV A


Page 14 of 15

Appendix 3 Test Coal Quality Record Coal Quality Record Testing time

Recorded by

Test condition

Unit

Load

MW

Total moisture M

%

Ash content Ag

%

Fixed carbon Cg

%

Volatile matter Vg

%

Q Dw

kcal.

combustible content in fly content

%

Combustible content in slag

%

Fineness of pulverized coal

%

Commissioning Contractor: Date: Contractor: Date: Owner

1

2

3

4

Date: Operation Contractor: Dongfang Electric: Date:

5

6

Date:



REV A


Page 15 of 15

Appendix 4 Pulverized Coal Fineness Record

Pulverized Coal Fineness Testing time

Recorded by

Test condition

Unit

Load

MW

Primary air flow at mill inlet

T/h

Primary air temperature at mill inlet

℃

Coal feeding flow

T/h

Outlet temperature of coal pulverizer separator

℃

Differential pressure through mill separator

KPa

Coal mill current

A


%


Mill A

Mill B

Mill C

Mill D


Mill E

Remark s

Date:



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-M-01-HH-002 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI


Check Design Scale


DETAIL DESIGN STAGE

Procedure of Burning Commissioning N/A

DWG No.


REV

A


Procedure of Burning Commissioning

REV A


Page 2 of 17


PURPOSE ..........................................................................................................................................................3

2.

SCOPE ...............................................................................................................................................................3

3.

PREPARATION BASIS.....................................................................................................................................3

4.

BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .............................................................................3

5.

TOOLS AND INSTRUMENT FOR COMMISSIONING.................................................................................4

6.

PREREQUISITE FOR COMMISSIONING......................................................................................................4

7.

MEASURES FOR COMMISSIONING ORGANIZATION .............................................................................6

8.

COMMISSIONING PROCEDURE...................................................................................................................7

9.

SAFETY MEASURES.......................................................................................................................................8

10.

9.1

Safety rules for commissioning.......................................................................................8

9.2

Personal Risk and Preventative Measures.......................................................................9

9.3

Equipment Risk and Preventative Measures...................................................................9 APPENDIX ................................................................................................................................................9

Appendix 1 Commissioning Condition Checklist.......................................................................10 Appendix 2 Boiler Combustion Parameter Adjustment Record .................................................13 Appendix 3 Opening Record for All Small Secondary Air Dampers .........................................14 Appendix 4 Furnace Temperature Record...................................................................................15 Appendix 5 Record of Oxygen Content in Flue Gas ..................................................................16 Appendix 6 Coal Quality Record ................................................................................................16 Appendix 7 Pulverized Coal Fineness Record............................................................................17


1.


REV A


Page 3 of 17

Purpose To perform initial burning adjustment on new boilers to ensure that the systems are able to operate safely and stably during commissioning. The requirements are that the burning conditions are stable and boilers are free of black smoke, serious coking, serious pollution and corrosion of convection flue gas pass. The test shall ensure that 30 day reliability operation can be carried out, provide certain operation experience for trial production and provide data for boiler performance test and normal unit operation for reference.

2.

Scope This procedure is applicable to boiler burning adjustment and commissioning. The following systems need be commissioned:

2.1

Adjustment of excess air factor (oxygen content):

2.2

Adjustment of burners’ swing angle and of secondary air dampers;

2.3

Adjustment of the fineness of pulverized coal;

2.4

Adjustment of primary and secondary air flowrate and flow velocity for burners;

2.5

Load distribution among burners;

2.6

Cold-state inspection of even primary air distribution among pulverized coal piping

3.

Preparation Basis

3.1

Combustion Adjustment and Test Method for Coal-fire Boilers;

3.2

Instruction manuals for boiler equipments;

3.3

Manual of combustion equipment;

3.4

Manual of coal mills;

3.5

Flue-gas and air system drawings.

4.


4.1

Boiler: Model DG1025/18.3-II13, natural circulation drum boilers with four-corner tangential firing. It has single furnace with half open arrangement of II Type, brown coal fired, single reheating, balanced ventilation

4.2

Temperature control mode: superheated steam is desuperheated by spraying water, and the swinging burner nozzle is used as the main way to adjust the steam temperature of the reheated steam, reducing temperature with water spray as auxiliary.

4.3

Model HP963 coal mills are used and five coal mills are provided for each boiler (when the design coal is fired, 4 coal mills operate and 1 coal mill is as standby).

4.4

Burner arrangement and type: Burners are arranged at four corners, the burner centerlines are tangential to two imaginary circles of furnace centerline, of which the diameters are 548mm and 1032 mm, respectively.

4.5

Main Boiler Parameters:



REV A


Page 4 of 17

Unit Generator output

Main steam

Reheat steam

BMCR

TMCR

TRL

75%TRL

50%TRL

MW

Flow

t/h

1025

976.19

927.80

678.00

467.50

Pressure

MPa

18.0

17.5

17.33

14.33

9.56

Temperature

℃

541

541

541

541

535

Flow

t/h

863.7

802.023

766.01

571.00

402.08

Inlet pressure

MPa

3.99

3. 625

3.54

2.66

1.85

Outlet pressure

MPa

3.80

3.438

3.38

2.53

1.76

Inlet temperature

℃

329

322

320

313

318

Outlet temperature

℃

541

541

541

541

515

℃

281

275.5

273

255

234

Temp. of feed water

5.


5.1

Walkie talkie；

5.2


5.3

Coal powder sampler

5.4

Oxygen analyzer;

5.5

Optical thermometer;

5.6

Anemometer

6.

Prerequisite for Commissioning Before formally beginning commissioning job, commissioning persons should conduct comprehensive checks with relevant units on conditions that should be available for commissioning of this system according to contents listed in Attachment 1 (Commissioning Condition Checklist) and make well the records.

6.1

Open and close test for flue gas & air baffle and steam & water valves (1)

Fully opened and closed to their limit positions;


6.2

6.3

6.4

6.5

6.6

6.7


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Page 5 of 17

(2)

Close and open in correct direction;

(3)

Correct status indication.

Cold ventilation test (1)

Primary air evenness measurement is complete;

(2)

Calibration of secondary air flow measurement devices is complete;

(3)

Calibration of air flow meters at coal mill inlets is complete

Interlock, protection, sequential control and audible and visual alarm test (1)

The auxiliary part has been tested;

(2)

The FSSS has been tested;

(3)

The interlock test for dampers is complete;

(4)

The relevant audible and visual alarm tests are complete.

Fuel Oil System (1)

The static commissioning of fuel oil systems is complete;

(2)

Separate operation, program-controlled startup and shutdown test of all oil guns are complete;

(3)

Interlock protection test of the fuel oil systems are complete.

Pulverizing Plant (1)

Static commissioning is complete

(2)

The operation test of dampers is complete;

(3)

Al interlock and protection test are complete.

Ash Blowing Systems (1)

Static commissioning of all ash blowers is complete;

(2)

Static commissioning of all ash blower PLCs are complete;

(3)

The ash blowing steam supply safety valves have been set.

Ash Handling System (1)

The valve operation test is complete;

(2)

The interlock test is complete;

(3)

The PLC test is complete;

(4)

Individual trial run is complete

6.8

The static commissioning of burners are complete;

6.9

The interlock test of flame scanning cooling air systems is complete;

6.10

The interlock test of turbines, boilers and electrical systems shows that the interlock relation is correct and operation is reliable.

6.11

The roads within the commissioning site must be free of obstructions. There is adequate lighting and reliable emergency illumination.



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6.12

Communication equipments at trial operation site are convenient and available.

6.13

Adequate fire-fighting appliances are available.

6.14

Sufficient maintenance personnel have been suitably trained.

6.15

Adequate maintenance tools and materials are available.

6.16

The tools for operation and record forms are available.

6.17

The commissioning instruments and meters are ready for use.

7.

Measures for Commissioning Organization This procedure shall be executed under the organization of commissioning contractor. The Contractors shall cooperate closely with each other according to their respective work responsibilities so as to guarantee safe and effective implementation of commissioning. Work responsibilities of the commissioning and Contractors are as follows:

7.1

7.2

7.3



◆


◆


◆


◆


◆


◆




◆


◆


◆


◆



7.4




◆



7.5

7.6

8.


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◆


◆


◆




◆


◆


◆


Responsibilities of the Owner ◆


◆


◆

Accept the results of commissioning 。

Commissioning Procedure In principle, adjustable parameters shall remain unchanged as possible except that the parameters of the individual test items may be changed

8.1

Adjustment of Excess Air Factor An excessively-large or excessively-small excess air factor will cause the increase in energy loss. Therefore, the excess air factor should be appropriate in order to minimize thermal loss. Oxygen content shall be adjusted mainly by changing total secondary air flow, and small secondary air dampers shall be used as auxiliary adjustment means to ensure that combustion is carried out at an appropriate excess air factor.

8.2

Adjustment of Burners’ Swing Angle and of Small Secondary Air Dampers An upward-sloping burner will provide a higher furnace combustion center, higher furnace outlet gas temperature, superheated and reheat steam temperature and cause burnout areas to move backward. However, if the burners slope excessively upward, the burnout areas will move backward significantly and cause more incomplete combustion loss and heat loss due to exhaust gas. In addition, a higher furnace outlet gas temperature may cause some unfavorable effects, such as coking at furnace outlet. When making adjustment the burner angle, the flue gas temperature deviation shall be recorded and adjusted. A downward-sloping burner will provide a lower furnace combustion center, lower furnace outlet gas temperature, and lower superheated and reheat steam temperature. When the situation is more serious, the exhaust gas temperature will be reduced and convection flue gas pass may experience low-temperature corrosion. Therefore, the burner swing angles shall be appropriately tuned and such adjustment shall be made together with adjustment of small secondary air dampers. If possible, ensure that adjustment will not cause significant combustion disturbance and sharp variation in steam temperature and pressure. If combustion is relatively concentrated and the temperature at combustion center is high, increase the opening of some small secondary air dampers of middle layer. If combustion is relatively decentralized and the temperature at combustion center is low, decrease the opening of some small secondary air dampers of middle layer. If a higher steam temperature requires



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burners to slope upward, appropriately increase the opening of upper-layer small secondary air dampers to ensure that pulverized coals are burnt out before leaving furnaces. 8.3

Adjustment of the fineness of pulverized coal Fine pulverized coal is advantageous to combustion and however coal mills will consume more electric energy. On the other hand, coarse pulverized coal cause more electric energy consumption and however disadvantageous to combustion. In order to attain optimum cost efficiency, an optimum fineness of pulverized coal shall be required also. For a newly-installed boiler, make all necessary effort to ensure that the fineness reaches the design value (R90=28%). The fineness of pulverized coal is adjusted mainly by adjusting coal mill separator dampers and air supply flow to coal mills. The mill discharge separators are adjusted by 50% firstly and the optimum state is achieved gradually. If appropriate fineness of pulverized coal can not be achieved still, comprehensive consideration shall be given to whether the hydraulic loading force of grinding rolls are proper, by taking account of coal mill output. Adjust the hydraulic loading force if necessary.

8.4

Adjustment of Primary and Secondary Air Flow and Velocity for Burners; An appropriate primary and secondary air flow and velocity of burners are required to establish normal aerodynamic field and stable combustion. An excessively-high air flow rate and velocity will postpone ignition while an excessively-low air flow rate and velocity will cause piping clogging and damage to burners etc. An excessively-high or excessively-low secondary air flow velocity will impair normal combustion and reasonable excess air factor and cause combustion to become unstable. In order to prevent primary air piping from clogged, it is necessary to ensure that certain primary air flow rate and velocity should be maintained, primary air velocity of all burners approach their design values and primary air flow at coal mill inlet is not lower than 60% rated flow during coal mill operation. An appropriate secondary air flow velocity requires that certain differential pressure should be maintained between secondary air tanks and furnace. At present, the differential pressure shall be about 700 to 900 Pa when the boiler load is more than 50% BMCR. In addition, the ratio of primary air flow rate to secondary air flow rate is very important. In general, this ratio shall be maintained around the design value. The ratio shall be adjusted mainly through adjustment made upon total primary and secondary air flow. However, in any case, the primary air flow entering each coal mill shall not be lower than 65% rated value to prevent clogging.

8.5

Load Distribution among Burners; Under high load, adjacent 3 or 4 coal mills shall run as possible. This is advantageous to combustion and even thermal load distribution among furnaces. When coal mills are running, all pulverized coal outlet piping at the same layer as coal mill must be put into operation.

8.6

Primary Air Evenness Measurement for Pulverized Coal Piping A fixed orifice is designed for pulverized coal piping at the discharge of each coal mill so that the primary air flow deviation is within ±5%.

9.

Safety Measures

9.1


9.1.1


9.1.2


9.1.3




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9.1.4

Combustion is associated with safe and stable operation of the units. Therefore, the test shall be organized and commanded on a uniform basis. Any individual shall not change the test procedures without approval.

9.1.5

All persons participating in commissioning shall abide by the associated safety rules strictly to ensure that the commissioning can be carried out safely and smoothly;

9.2


9.2.1

Flame observers shall communicate frequently with CCR operators. Flame observers shall use correct methods to avoid burns.

9.3


9.3.1

During the test, operating condition shall not exhibit significant change to avoid flameout and other major accidents.

9.3.2

During the test, the cooperating condition shall remain stable and the furnace shall operate under negative pressure.

9.3.3

During the test, stop ash blowing.

9.3.4

During the test, various measurement and record on the same operating condition shall be carried out simultaneously as possible and error shall be minimized.

10.

Appendix



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Appendix 1 Commissioning Condition Checklist

No.

1

2

3

4

5

6

7

Items

Requirements

Flue gas and air baffle, steam and water valve Operation test

Fully opened and closed to their limit positions;

□Yes □No

Close and open in correct direction

□Yes □No

Correct status indication.

□Yes □No

Primary air evenness measurement is complete

□Yes □No

Calibration of secondary air measurement devices is complete

□Yes □No

Cold test

ventilation

Interlock, protection, sequential control, audible and visual alarm test

Burners

Fuel oil system

Pulverizing plant

Ash Systems

blowing

Result

flow

Calibration of air flow meters at coal mill inlets is complete

□Yes □No

The auxiliary part has been tested;

□Yes □No

The FSSS test is complete

□Yes □No

The interlock test of valves and dampers is complete

□Yes □No

The relevant audible and visual alarm tests are complete

□Yes □No

The static commissioning of burners are complete;

□Yes □No

The static commissioning of fuel oil systems is complete;

□Yes □No

Separate operation, program-controlled startup and shutdown test of all oil guns are complete;

□Yes □No

Interlock protection test of the fuel oil systems are complete

□Yes □No

The static commissioning is complete

□Yes □No

The operation test of dampers are complete

□Yes □No

All interlock and protection tests are complete

□Yes □No

Static commissioning of ash blowers are complete;

□Yes □No

Static commissioning of all ash blower PLCs are complete;

□Yes □No

The ash blowing steam supply safety valves have been set.

□Yes □No

Verified by

Remar ks



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Appendix1.Commissioning Condition Checklist (continued)

No.

8

Items

Ash handling system

Requirements

Result

The valve operation tests are complete

□Yes □No


□Yes □No

The PLC test is complete;

□Yes □No

Individual trial run is complete

□Yes □No

9

Flame scanning cooling air system


□Yes □No

10

Combined interlock test covering the turbine, boilers and electrical systems

Correct interlock relation Actuation reliable

□Yes □No

11

Road at trial operation site

The passage is clear of any obstacle and well lighted Emergency lighting reliable

□Yes □No

12

Communication equipments at trial operation site

Convenient and usable

□Yes □No

13

Fire apparatus

Sufficient

□Yes □No

14


Sufficient and trained

□Yes □No

15

Maintenance tools and materials

Sufficient

□Yes □No

16

Tools for operation and record forms.

Prepared

□Yes □No

17

Test instruments and meters


Prepared

Verified by

□Yes □No


Date:

Remar ks



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Appendix 2 Boiler Combustion Parameter Adjustment Record

Time Name Main steam flow Main steam pressure Main steam temperature drum pressure Drum level Feed water flow Feed water pressure Temp. of feed water IDF current (A/B) Opening of IDF inlet damper (A/B) FDF current (A/B) FDF dynamic blade opening (A/B) Primary air fan current (A/B) A/B primary air fan guide blade opening A/B FD fan outlet air pressure (A/B) Air preheater outlet air pressure (A/B) No. of coal mill Primary air flow at mill inlet Primary air temperature at mill inlet Coal feeding flow Mill outlet temperature: Differential pressure through mill separator Coal mill current Fineness of pulverized coal Opening of mill separator damper Commissioning Contractor: Date: Contractor: Date: Owner

Combustion Parameter Adjustment Record Electric load Unit Data Name T/H Reheater outlet pressure MPa Reheater outlet pressure Reheater temperature ℃ 1st stage desuperheating MPa water flow 2nd stage desuperheating mm water flow 3rd stage desuperheating T/h water flow MPa Micro water spray flow Emergency desuperheating ℃ water flow Flue gas temperature at A economizer inlet Flue gas temperature at air % preheater inlet A Temp. of flue gas % A % % KPa Unit T/H

Burner’s angle of swing Primary air damper of air preheater outlet Secondary air tank pressure Oxygen content

Data

T/H T/H T/H T/H T/H ℃ ℃ ℃ % KPa KPa %

Primary air pressure Coal Mill Parameters A B

Unit MPa MPa ℃

C

KPa D

E

℃ T/H ℃ KPa A % % Date: Operation Contractor: Dongfang Electric: Date:

Date:



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Appendix 3 Opening Record for All Small Secondary Air Dampers

Opening Record for All Small Secondary Air Dampers Time

Load

Small secondary air damper at all layers

Unit

OFA top secondary air

%

Secondary air at Layer EE

%

Surrounding air at Layer E

%

Secondary air at Layer DE (oil)

%

Surrounding air at Layer D

%

Secondary air at Layer DD

%

Secondary air at Layer CC

%

Surrounding air at Layer C

%

Secondary air at Layer BC (oil)

%

Surrounding air at Layer B

%

Secondary air at Layer AB (oil)

%

Surrounding air at Layer A

%

Secondary air at % Layer AA Commissioning Contractor: Date: Contractor: Date: Owner

#1 Corner

#2 Corner

#3 Corner


#4 Corner

Date:



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Appendix 4 Furnace Temperature Record

Furnace Temperature Record Time Position Elevation (mm)


Load Side A 1

2

Side B 3

4

1


2

3

Date:

4



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Appendix 5 Record of Oxygen Content in Flue Gas Record of Oxygen Content in Flue Gas Time

Load

Measurement point

1


2

3

4

5

6


7

8

Date:

Appendix 6 Coal Quality Record Coal Quality Record Testing time

Recorded by

Test condition

Unit

Load

MW

Total moisture M

%

Ash content Ag

%

Fixed carbon Cg

%

Volatile matter Vg

%

Q Dw

kcal.

combustible content in fly content

%

Combustible content in slag

%


%


1

2

3


4

5

Date:

6



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Appendix 7 Pulverized Coal Fineness Record

Fineness of Pulverized Coal Testing time

Recorded by

Test condition

Unit

Load Primary air flow at mill inlet Primary air temperature at mill inlet Coal feeding flow Outlet temperature of coal pulverizer separator Differential pressure through mill separator Coal mill current Fineness of pulverized coal

MW T/H ℃ T/H

Commissioning Contractor: Date: Contractor: Date: Owner:

Mill A

Mill B

Mill C

Mill D

Mill E

℃ KPa A %


Date:

Remark s



Owner’s DWG No.

PT.PLN(PERSERRO)

0702-00-M-01-HLB-001 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI


CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY Sichuan Electric Power Commissioning & Test Institute Approva l Review Date

Check Design Scale


DETAIL DESIGN STAGE

Commissioning Procedure of Induced Draft Fan System N/A

DWG No.

SCCTI-TS-GL-CS-005-200 9A

REV

A

PLTU 1 BANTEN（2×315MW） Project Commissioning Procedure

Procedure of Induced Draft Fan System

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PURPOSE ........................................................................................................................................... 3

2.

SCOPE ................................................................................................................................................ 3

3.


4.


5.


6.


7.


8.


9.

SAFETY MEASURES..................................................................................................................... 15

9.1


9.2


9.3


10.

10.1


10.2

Appendix 2 Trial Operation Parameters of IDF and Its System....................... 19

10.3

Appendix 3 IDF Dampers Commissioning Record.......................................... 20

10.4

Appendix 4 Control Damper Commissioning Record of IDF and Its System . 22



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1.

Purpose

1.1


1.2

Check electrical and I&C protection interlock devices and signal devices and confirm that their actions are correct and reliable.

1.3

Check the operation conditions of equipment. Examine performance of system so as to find out and eliminate possible defects.

2.

Scope This procedure is applicable for the commissioning of induced draft fan subsystem, including such items as the confirmation of air damper, interlocking and protection test, system commissioning and dynamic adjustment.

3.

Preparation Basis

3.1

Operation manual of induced draft fan

3.2

Boiler flue gas system diagram

3.3

Control logic diagram on induced draft fan

4.


4.1

There are two operating induced draft fans. The stationary blade damper at the inlet of fan is employed to control the pressure of boiler furnace.

4.2

Technical parameters of induced draft fan Model of fan: AN-25/V13+2.5

Axial-flow type

Name

Unit 3

Flow at inlet of fan

4.3

4.4

m /s 3

TB

BMCR

TMCR

290.8

246．7

239.8

Medium density

Kg/ m

0.869

0.869

0.867

Total pressure of fan

PA

5796

4456

4093

Shaft power of fan

KW

1912

1251

1143

Total pressure efficiency of fan

%

85．5

85．8

84.5

Rotating speed

r/min

990

990

990

Technical Parameters of Motor Model of motor

YKK710-6TH-W

Rated voltage

6300V

Rated power

2150 KW

Rated speed

990 r/min

Rated voltage

380V

Technical parameters of cooling fan Model of fan

G9-19№5A



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Rated power

11 KW

5.


5.1

Walkie talkie;

5.2


5.3

Digital multimeter;

5.4

Temperature measurement meter;

5.5

Tachometer;

5.6

Sound intensity meter.

6.

Prerequisite for Commissioning

Rated speed

2960 r/min

Before formally beginning commissioning job system by system, commissioning persons should conduct comprehensive checks on conditions that should be available for commissioning of this system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and make well the records. 6.1

Environmental condition

6.1.1

Within the scope of system, the site should be level, the road should be clear, the trench cover is complete and the environment is clean and free of sundries.

6.1.2


6.1.3

The sufficient formal illumination is provided on site, if necessary, the temporary illumination should be installed additionally.

6.1.4

The reliable communication equipments are provided on site.

6.1.5

The sufficient firefighting appliances are provided on site.

6.2


6.2.1

The installation and heat insulation work of all the equipments, pipelines and auxiliary systems have been completed;

6.2

The single commissioning for the induced draft fan is qualified;

6.2.3

The installation and commissioning for the cooling fan are completed;

6.2.4

The installation and commissioning for the industrial cooling water system are completed;

6.2.5

The sundries inside the induced draft fan and system are cleared clean;

6.2.6

The equipment and each valve have been tagged and named, conforming to the system.

6.2.7

Each manhole door inside the system is closed.

6.3

Necessary conditions for electrical and I&C

6.3.1

After the measuring points and measuring elements inside the system are qualified subject to calibration, the installation and commissioning are completed and provided with the application conditions.

6.3.2

After the commissioning for the cooling fan is competed, the favorable operation condition,



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normal parameters and the correct display of CRT state have been confirmed. 6.3.3

When single commissioning of the valve is completed, the on/off actions are normal and the on-site location of the limit switch and display of the CRT state are correct.

6.3.4

The interlock protection alarm test for the induced draft fan system is completed.

6.3.5

The electrical test of motor is qualified, after 2 hour no-load running, the condition is favorable and the turning direction is correct.

6.4

Other necessary conditions

6.4.1

The joint inspection is performed through organizing such related parties as construction, Dongfang Electric, Owner and production as well as commissioning; the problems found should be coped completely.

6.4.2

The preparation work for production and commissioning is completed; the operators should be arranged completely and qualified via the training and examination. The operation regulation and system diagram are reviewed and approved; the operating tools and the operation log are prepared properly.

6.4.3

The necessary maintenance tools and materials are prepared;

6.4.4

The command and organizing system for commissioning is perfect, with explicit division of labor.

6.4.5

The commissioning data, tools, instruments, gauge and the record list are prepared completely;

6.4.6

The personnel on instrument control, electrical and maintenance from the installation organization arrive at the site.

6.4.7

The disclosure work on measures is completed.

7.


7.1

7.2



◆


◆


◆


◆


◆


◆





7.3

7.5

7.6

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◆


◆


◆


◆



7.4





◆


◆


◆


◆




◆


◆


◆




◆


◆


8.


8.1

Cold check and transmission test of damper

8.1.1

Check the motorized or pneumatic on-off damper and enter the following data on the records: Check whether KKS code, designation, local position indications are correct and whether the remote operation direction and feedback are correct; the on/off time of damper, test date, signature by person in charge of test. Refer to Appendix 4 for other contents.

8.1.2

Check the motorized or pneumatic regulating valves and enter the following data on the records;



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KKS code, designation, local position indications and feedback indications corresponding to upward command of 0%, 50%, 75%, and 100% and downward command of 100%, 75%, 50%, and 0% respectively, confirm if local position indication is correct, test date, signature by person in charge of test. Refer to Appendix 3 for other requirements. 8.2

Check Interlock Protection and Alarms (note: the test item on interlock protection is based on the discuss result on logic.)

8.2.1

The power supply of the induced draft fan shall be placed in the test location to inspect the items below: (1) Start-up induced draft fan through computer and feedback on computer is correct; (2) Suspending the induced draft fan through computer and feedback on computer is correct; (3) Reliable emergency buttons

8.2.2

The interlock protection test of the induced draft fan covers:

8.2.2.1

Inspection for the opening condition of air passage

No.

Test item

Opening of A side air passage (1)

All the secondary dampers are in the purging location.

(2)

The inlet damper of induced draft fan A has been opened, the stationary blade at the inlet of induced draft fan A has not been closed properly and the outlet damper of induced draft fan A has been opened.

(3)

The moving blade of the forced draft fan A hasn’t been closed properly, the outlet damper of the forced draft fan A has been opened, the interconnection valve at the outlet has been opened or the secondary damper at the outlet of air preheater has been opened;

(4)

The single-plate flue damper at the inlet of air preheater A has been opened or the air preheater is operating.

Opening of B side air passage (1)

All the secondary dampers are in the purging location.

(2)

The inlet damper of induced draft fan B has been opened, the stationary blade at the inlet of induced draft fan B has not been closed properly and the outlet damper of induced draft fan B has been opened.

(3)

The moving blade of the forced draft fan B hasn’t been closed properly, the outlet damper of the forced draft fan B has been opened, the interconnection valve at the outlet has been opened or the secondary damper at the outlet of air preheater B has been opened;

(4)

The single-plate flue gas damper at the inlet of air preheater B has been opened or the air preheater B is operating.

Fixed value

Results

Remarks


8.2.2.2 No.


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Inspection for allowable condition of induced draft fan A (B) Test item

Inspection for allowable condition of induced draft fan A (1)

Induced draft fan A is free of tripping condition;

(2)

Opening of B side air passage

(3)

The air preheater A is operating and the flue gas damper at the inlet has been opened.

(4)

The stationary blade at the inlet of induced draft fan A has been closed;

(5)

The electric damper at the inlet of induced draft fan A has been opened;

(6)

The control damper at the inlet of induced draft fan A has been closed;

(7)

The electric damper at the inlet of induced draft fan A has been closed;

(8)

The temperature of bearing for the induced draft fan A is normal;

(9)

The temperature of motor bearing for the induced draft fan A is normal;

(10)

The temperature of stator coil of motor for the induced draft fan A is normal;

(11)

Any cooling fan of the induced draft fan A is operating

(12)

Free of request of FSSS natural ventilation

Inspection for allowable condition of induced draft fan B (1)

Induced draft fan B is free of tripping condition;

(2)

Opening of A side air passage

(3)

The air preheater B is operating and the flue gas damper at the inlet has been opened.

(4)

The electric damper at the outlet of induced draft fan B has been opened;

(5)

The control damper at the inlet of induced draft fan B has been closed;

(6)

The electric damper at the inlet of induced draft fan B has been closed;

(7)

The temperature of bearing for the induced draft fan B is normal;

(8)

The temperature of motor bearing for the induced draft fan B is normal;

(9)

The temperature of stator coil of motor for the induced

Fixed value

Results

Remarks



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Page 9 of 22

draft fan B is normal; (10)

Any cooling fan of the induced draft fan B is operating

(11)

Free of request of FSSS natural ventilation

8.2.2.3 No.

Inspection on tripping condition for the protection interlinking of induced draft fan Test item

Fixed value

Tripping condition of induced draft fan A (1)

After the induced draft fan A operates for 60s, the electric damper at the outlet of induced draft fan A is closed;

(2)

After the induced draft fan A operates for 60s, the electric damper at the inlet of induced draft fan A is closed;

(3)

The bearing temperature of the induced draft fan A is high high.

(4)

The motor bearing temperature of the induced draft fan A is high high.

(5)

The vibration of bearing in X-direction at the driving end of induced draft fan A is high

6.3mm/s

(6)

The vibration of bearing in Y-direction at the driving end of induced draft fan A is high

6.3mm/s

(7)

The vibration of bearing in X-direction at the non-driving end of induced draft fan A is high

6.3mm/s

(8)

The vibration of bearing in Y-direction at the non-driving end of induced draft fan A is high

6.3mm/s

(9)

The furnace pressure of FSSS is low;

(10)

Emergency button action;

(11)

After the induced draft fan A operates for 60s, two cooling fans suspends completely;

(12)

The stationary blade is greater than 15%, and the induced draft fan A is stalling.

(13)

Air preheater A suspends

Tripping condition of induced draft fan B (1)

After the induced draft fan B operates for 60s, the electric damper at the outlet of induced draft fan B is closed;

(2)

After the induced draft fan B operates for 60s, the electric damper at the inlet of induced draft fan B is closed;

(3)

The bearing temperature of the induced draft fan B is high high.

(4)

The motor bearing temperature of the induced draft fan B

Results

Remarks



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is high high. (5)

The vibration speed of motor bearing for the induced draft fan B is high high.

(6)

The vibration of bearing in X-direction at the driving end of induced draft fan B is high high

(7)

The vibration of bearing in Y -direction at the driving end of induced draft fan B is high high

(8)

The vibration of bearing in X-direction at the non-driving end of induced draft fan B is high high

(9)

The vibration of bearing in Y-direction at the non-driving end of induced draft fan B is high high

(10)

The furnace pressure of FSSS is low low;

(11)

Emergency button action;

(12)

After the induced draft fan operates for 60s, two cooling fans suspends completely;

(13) The stationary blade is greater than 15%, and the induced draft fan B is stalling. (14)

8.2.3 No.

Air preheater B suspends

Inspection for alarm condition of induced draft fan Test item

Alarm condition of induced draft fan A (1)

The bearing temperature of the induced draft fan A is high.

(2)

The motor bearing temperature of the induced draft fan A is high.

(3)

The motor stator temperature of the induced draft fan A is high.

(4)

The vibration speed of motor bearing for the induced draft fan A is high.

(5)

The vibration of bearing in X-direction at the driving end of induced draft fan A is high

(6)

The vibration of bearing in Y-direction at the driving end of induced draft fan A is high

(7)

The vibration of bearing in X-direction at the non-driving end of induced draft fan A is high

(8)

The vibration of bearing in Y-direction at the non-driving end of induced draft fan A is high

(9)

Induced draft fan A is stalling.

Fixed value

Results

Remarks



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Alarm condition of induced draft fan B (10)

The bearing temperature of the induced draft fan B is high.

(12)

The motor bearing temperature of the induced draft fan B is high.

(13)

The motor stator temperature of the induced draft fan B is high.

(14)

The vibration speed of motor bearing for the induced draft fan B is high.

(15)

The vibration of bearing in X-direction at the driving end of induced draft fan B is high

(16)

The vibration of bearing in Y-direction at the driving end of induced draft fan B is high

(17)

The vibration of bearing in X-direction at the non-driving end of induced draft fan B is high

(18)

The vibration of bearing in Y-direction at the non-driving end of induced draft fan B is high

(19)

Induced draft fan B is stalling.

8.2.2.4 No.

Interlock test for cooling fan of induced draft fan Test item

(1)

1# cooling fan of induced draft fan A

1）

Startup permissive conditions: in remote control location

2）

Shutdown permissive conditions (or): Shutdown of induced draft A 2# cooling fan of induced draft fan A is operating

3）

Interlock startup conditions： 2# cooling fan is operating and the bearing temperature of induced draft A is greater than 90℃, 1# cooling fan is started by means of interlock. Emergency tripping for 2# cooling fan; 1# cooling fan is started by means of interlock. Starting the 1# cooling fan in program control

(2)

2# cooling fan of induced draft fan A

1）

Startup permissive condition: in remote control location

2）

Shutdown permissive conditions (or): Shutdown of induced draft A 1# cooling fan of induced draft fan A is operating

Fixed value

Results

Remarks


3）


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(3)

1# cooling fan of induced draft fan B

1）

Startup permissive conditions ： location

2）

Shutdown permissive conditions (or):

in remote control

Suspension of induced draft B 2# cooling fan of induced draft fan B is operating 3）


(4)

2# cooling fan of induced draft fan B

1）

Startup permissive conditions ： location

2）

Shutdown permissive conditions (or):

in remote control

Shutdown of induced draft B 1# cooling fan of induced draft fan B is operating 3)

Interlock startup conditions： 1# cooling fan is operating and the bearing temperature of induced draft B is greater than 90℃, 2# cooling fan is started by means of interlock. Emergency tripping for 1# cooling fan; 2# cooling fan is started by means of interlock. Starting the 2# cooling fan in program control

8.2.2.5 No. (1)

The damper at the inlet and outlet of induced draft fan as well as the interlock test of stationary blade Test item This side induced draft fan starts and operates; 30s is

Fixed value

Results

Remarks



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delayed to lock and open the inlet damper and outlet damper of this side induced draft fan; meanwhile, if another side induced draft fan doesn’t operate, the inlet damper and outlet damper as well as the stationary blade of another side induced draft fan are closed by means of interlock.

(2)

(3)

8.2.2.6 No.

The two air induced draft fans are outage, 135s is delayed for FSSS protection to lock and open the inlet damper and out let damper as well as the stationary blade for two induced draft fans. This side air induced draft fan is outage; the air induced draft at other side is operating, the inlet damper and outlet damper as well as the stationary blade for this side induced draft fan are closed by means of interlock

Interlock test for the interconnection valve at the outlet of electric precipitator Test item

(1)

Conditions for interlock opening:

(2)

Induced draft A and B suspend uniformly, delayed for 80s.

(2)

Conditions for interlock close ( following conditions or)

Fixed value

Results

Remarks

The air preheater A suspends and the induced draft fan B operates or The air preheater A suspends and the induced draft fan A operates or The induced draft fan A suspends for 65s and the induced draft fan B operates , and The flue gas damper actuator at the outlet of induced draft fan A is not closed, and the stationary blade at inlet of induced draft A is not closed properly or the induced draft B suspends for 65s. The induced draft fan A is operating, the actuator of the flue gas damper at the outlet of induced draft fan B is not closed and the stationary blade at the inlet of induced draft B is not closed properly.

8.2.2.7 No.

Procedure on sequence control startup and shutdown for the induced draft fan Test item

Procedure on sequence control startup for the induced draft fan A (1)

Step 1: start the cooling fan of induced draft fan A

(2)

Step 2: close the inlet damper of induced draft fan A; The stationary blade at the inlet of induced draft fan A is closed up to the minimum location;

Fixed value

Results

Remarks



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Open the outlet damper of induced draft fan A (3)

Step 3:

start the induced draft fan A

(4)

Step 4: open the inlet damper of induced draft fan A

Procedure on sequence control shutdown for the induced draft fan A (1)

Step 1: the stationary blade at the induced draft fan A is located in the minimum location;

(2)

Step 2: induced draft fan A suspends

(3)

Step 3: close the electric dampers at the inlet and outlet of the induced draft fan A

Procedure on sequence control startup for the induced draft fan B (1)

Step 1: start the cooling fan of induced draft fan A

(2)

Step 2: close the inlet damper of induced draft fan A; The stationary blade at the inlet of induced draft fan A is closed up to the minimum location; Open the outlet damper of induced draft fan A

(3)

Step 3:

(4)

Step 4: open the inlet damper of induced draft fan A

start the induced draft fan A

Procedure on sequence control shutdown for the induced draft fan B (1)

Step 1: the stationary blade at the induced draft fan A is located in the minimum location;

(2)

Step 2: induced draft fan A suspends

(3)

Step 3: close the electric dampers at the inlet and outlet of the induced draft fan A

8.3

Commissioning and shutdown of the induced draft fan and system

8.3.1


8.3.1.1

Various interlock tests for the induced draft fan and system is confirmed to be qualified;

8.3.1.2

The power transmission of the inlet and outlet dampers of the induced draft fan as well as the inlet regulating damper is confirmed and the switch is flexible; and the local openness is consistent with the display of CRT.

8.3.1.3

The qualified lubrication oil has been filled for various bearings of the induced draft fan;

8.3.1.4

The commissioning conditions are confirmed to be provided for the cooling fan;

8.3.1.5

Various kinds of meters for the fan has been confirmed to be put into operation;

8.3.2

Commissioning for the induced draft fan and the systems

8.3.2.1

Start one cooling fan;

8.3.2.2

The allowable conditions for starting of the induced draft fan are confirmed to be met;

8.3.2.3

Start up induced draft fan；

8.3.2.4

Open the greater damper at inlet of fan and the outlet damper;



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8.3.2.5

Adjust the stationary blade of fan and control the pressure of furnace;

8.3.3

Suspension of air draft fan and its system

8.3.3.1

The stationary blade of the fan is closed up to the minimum location;

8.3.3.2

Suspend the fan;

8.3.3.3

Close the inlet and outlet dampers at inlet of fan

8.3.3.4

Suspend the cooling fan in delay;

8.4

Operation for the system during startup of complete set of system; Based on the dead load stage, on-load stage and full load stage as well as the 30d reliable operating stage, the operation reliability of the system should be tested; (1) Dynamic regulation of system：in the process of system commissioning, especially when the negative pressure adjusting of the furnace is operated, the monitoring on the equipment should be strengthened to ensure that the system is in the optimal operation state. (2) Complete trial operation record：The main parameters during starting the commissioning refer to Appendix 2;

9.

Safety Measures

9.1


9.1.1

The parties participating in commissioning shall be familiar with and abide by the relevant safety rules on site, and wear reasonable clothing and appropriate personal protective equipments.

9.1.2


9.1.3


9.1.4

All professional staffs shall be on respective duties during the whole commissioning to guarantee the safe operation of equipments.

9.2


9.2.1


9.3


9.3.1

When the induced draft fan and the system start up the commissioning for the first time, the relevant personnel must be designated to strictly monitor the equipment site, and the reliable communication means shall be employed to contact with the central control room.

9.3.2

When the induced draft fan is commissioning, the start time and current should be strictly monitored; if the start time is too long or the current swings abnormally, stop the operation timely;



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9.3.3

When starting the fan, the rotating direction should be noticed, if the turning direction is opposite, suspend the operation timely;

9.3.4

Take notice of monitoring the variation of such parameters as current, vibration and bearing temperature to avoid producing the severe accidents.

10.

Appendix


10.1 No.


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Appendix 1 Commissioning Condition Checklist Items

Requirements

Result

1.

Environmental conditions

(1)



□Yes □No

(2)

Platform, ladder, handrail, guard plate and construction scaffold

Complete Demolishing

□Yes □No

(3)

Illumination

Sufficient

□Yes □No

(4)


Reliable

□Yes □No

(5)

Fire apparatus

The quantity is sufficient and application is convenient

□Yes □No

2.

Maintenance conditions

(1)

Installation and heat insulation work

All fulfilled

□Yes □No

(2)

Commissioning of fan monomer

Qualified

□Yes □No

(3)

Lubrication oil of bearing

Completing the filling

□Yes □No

(4)

Commissioning of cooling fan

Qualified

□Yes □No

(5)


Debugging is completed and commissioning can be performed.

□Yes □No

(6)

Inner sundries ( including the boiler body and electric precipitator

Completing the clearing

□Yes □No

(7)

Equipment and valve

Listing, correct name

□Yes □No

(8)

Manhole door

Closed fully

□Yes □No

3.

Electrical and I&C condition

(1)

Measuring points and the measuring gauge

The calibration is qualified and the indication is correct

□Yes □No

(2)

Control for the cooling fan

The operation status is favorable, the display of status is correct

□Yes □No

Single valve

After completing the commissioning, the action is normal, the display of status is correct.

□Yes □No

(3)

Verified by

Remarks



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Test eligible

□Yes □No

(5)


The test is qualified, subject to 2-h no-loading operation, the condition is favorable and the rotary direction is correct.

□Yes □No

4.

Other conditions

(1)

Inspection work of system

Completed, the treatment of defects is completed;

□Yes □No

(2)


The operators are provided completely, the operation tools are prepared properly and the operation log is prepared properly.

□Yes □No

(3)


Complete

□Yes □No

(4)

Command and organization system

Perfect, the division of work is explicit.

□Yes □No

(5)

Commissioning data, tools, instruments, meters and record form,

Preparation is complete

(6)


Sufficient quantity and qualified training

□Yes □No

(7)

Disclosure of measures

Fulfilled

□Yes □No

(4)


Contractor:

Date:

Date:

□Yes □No


Dongfang Electric:

Date:

Date:


10.2


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Appendix 2 Trial Operation Parameters of IDF and Its System Trial Operation Parameters of IDF and Its System

No.

Item

Unit

1

Open position of control damper at inlet of IDF A

%

2

Open position of control damper at inlet of IDF B

%

3

Motor current of IDF A

A

4

Motor current of IDF B

A

5

The inlet air pressure of IDF A

KPa

6

The inlet air pressure of IDF B

KPa

7

The difference pressure between outlet and inlet of IDF A

KPa

8

The difference pressure between outlet and inlet of IDF B

KPa

9

Bearing vibration of IDF A

mm/s

10

Bearing vibration of IDF B

mm/s

11

Bearing temperature of IDF A

℃

12

Bearing temperature of IDF B

℃

13

Motor bearing temperature of IDF A

℃

14

Motor bearing temperature of IDF B

℃

15

Motor winding temperature of IDF A

℃

16

Motor winding temperature of IDF B

℃

17

Outlet gas temperature

℃

Data

Remarks


10.3


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Appendix 3 IDF Dampers Commissioning Record IDF Dampers Commissioning Record

KKS code

Name

X0HNA11AA001aXB

Inlet damper1, ID fan A

X0HNA11AA001bXB

Inlet damper2, ID fan A

X0HNA12AA001aXB

Outlet damper1, ID fan A

X0HNA12AA001bXB

Outlet damper2, ID fan A

X0HNA21AA001aXB

Inlet damper1, ID fan B

X0HNA21AA001bXB

Inlet damper2, ID fan B

X0HNA22A001aXB

Outlet damper1, ID fan B

X0HNA22A001bB

Outlet damper, ID fan B

X0HNA13AA001XB

ELEC PRECIPITATOR INTERCONNECTING MOTOR SHUT-OFF DAMPER

X0HNA11AA001aXB

ELEC PRECIPITATOR A OUTL MOTOR SHUT-OFF DAMPER 1


Remote Direction

Feedback

Time Direction

Feedback

Remote

Date

Signatu Remark re s


X0HNA11AA001bXB


X0HNA21AA001aXB


X0HNA21AA001bXB



Date:

Date:


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Date:

Date:


10.4


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Appendix 4 Control Damper Commissioning Record of IDF and Its System Control Damper Commissioning Record of IDF and Its System KKS KKS code

X0HNC11AA101XB X0HNC12AA01XB

0%

25%

50%

75%

100%

75%

50%

The inlet control damper of IDF A The inlet control damper of IDF B


Feedback corresponding to input value while rising and falling

Name

Date:

Date:


Date:

Date:

25%

0%

Date

Result

Signature

Remarks



PT.PLN(PERSERRO) PT REKADAYA ELEKTRIKA


Owner’s DWG No.

0702-00-M-01-QH-001 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI

CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) Commissioning & Test Project Institute Check Procedure of Start-up Boiler Design Scale N/A DWG No. SCCTI-TS-GL-CS-006-2009A

DETAIL DESIGN STAGE REV

A


Procedure of Start-up Boiler

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Table of Contents

1.

Purpose ............................................................................................................. 3

2.

Scope .................................................................................................................. 3

3.

Preparation Basis ................................................................................................ 3

4.

Brief Description of System and Equipment...................................................... 3

5.

Tools and Instrument for Commissioning .......................................................... 4

6.

Prerequisite for Commissioning ......................................................................... 4

7.

Measures for Commissioning Organization....................................................... 7

8.

Commissioning Procedure.................................................................................. 9

9.

Safety Measures................................................................................................ 28

9.1


9.2


9.3

Equipment Risk and Preventative Measures .................................................... 29

10.

Appendix .......................................................................................................... 30

10.1


10.2

Appendix 2 Format for Trial Run Record ........................................................ 36

10.3

Appendix 3 Pressure boosting curve-boiling out ............................................. 37

10.4

Appendix 4 Pipeline Blowing System Diagram............................................... 38

10.5

Appendix 5 Check list of dampers ................................................................... 39

10.6

Appendix 6 Check List of Control Dampers.................................................... 40



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1.

Purpose

1.1


1.2

Check the reliability of electric and I&C interlock protection and signal device.

1.3


2.

Scope The procedure is applicable to commissioning of startup boiler, including check and confirmation of adjustment condition, valve baffle test, interlock protection test, drying, boiling, pipe blowing and steam tightness test of startup boiler, safety valve calibration, normal operation and shutdown of the boiler.

3.

Preparation Basis

3.1

Operation Manual for Startup Boiler

4.


4.1

Brief introduction of the System One 40t/h oil-fired start-up boiler, produced by Jiangsu Shuangliang Boiler Co., Ltd., is equipped in PLTU 1 Jatim-Pacitan (2×315MW) Project. Model: SZS40-1.25/350-YC water tube oil-fired package boiler.

4.2

Main Technical Specifications of System Device

4.2.1

Main Technical Specifications of Boiler: No. 1

Name

Unit

Values

Boiler Parameter

(1)

Boiler Maximum Continuous Rating

T/h

40

(2)

Outlet Steam Pressure

MPa

1.25

(3)

Outlet Steam Temperate

℃

350

(4)

Inlet Water Temperature of Economizer

℃

20

(5)

Temp of flue gas

℃

≤160

(6)

Oil Pressure of Furnace

MPa

5.3

%

92.7

2 (1)

Technical Performance Boiler Efficiency



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No.

4.2.2

Name

Unit

Values

kW

165

%BMCR

30～100

(2)

Gross Power of Supporting Auxiliaries

(3)

Load Change Scope

(4)

Steam Temperature Deviation Range

℃

345～370

(5)

Boiler Blowdown Rating

%

≤2

(6)

Type and Arrangement of Burner

/

Split type atomizer burner, single and front wall arrangement

Type of Steam Boiler Auxiliaries (1)

Forced draft fan: supplied by boiler manufacturer, GMB-32, 43000m3/h, 6000pa, 110KW, 380v

(2)

Water feed pump: supplied by boiler manufacturer, DG46-30×8, 46m3/h, 2.0Mpa, 55KW, 380v

(3)

Deaerator: supplied by boiler manufacturer, QR40, 25m3, 40T/h

(4)

Blowdown flash tank: supplied by boiler manufacturer, DP-3.5, 3.5 m3, 127℃

5.


5.1

Walkie talkie;

5.2


5.3

Digital multimeter;

5.4

Handheld thermodetector

6.


6.1

Prerequisite Required before Trial Operation of System

6.1.1

Flue Gas and Air System (1)

Boiler air pressure test has been successfully completed through acceptance or each air leakage has been treated.

(2)

Boiler proper and flue gas duct have been assembled and insulated.

(3)

Individual commissioning and subsystem commissioning of forced draft fan have been completed.

(4)

All dampers of flue gas and air systems have been inspected, adjusted and accepted.


6.1.2

6.1.3


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Fuel Oil System (1)

System has been assembled and individual commissioning has been completed.

(2)

System hydraulic pressure test and water flushing has been completed successfully.

(3)

Compressed air pipeline and valves for blowing should be assembled and tested.

(4)

All motorized valves and pneumatic valves for systems have been tested and accepted.

(5)

The burner has been assembled and tested.

(6)

All interlock protection simulation test for systems have been successfully completed

(7)

The ON/OFF tests for all oil guns and high-energy igniters have been successfully completed.

(8)

Static commissioning for all flame detectors has been completed.

Boiler Proper (1)

Boiler proper have been installed, insulated and accepted;

(2)

Individual commissioning and interlock protection test for water feed pump have been completed.

(3)

Hydrostatic tests of the boilers have been successfully completed;

(4)

The drain, vent, blowdown and nitrogen charging systems of the boilers have been installed and insulated. All motorized valves have been tested and accepted.

(5)

After hydrostatic tests, hydraulic valve spools have been removed from all safety valves of the drums and superheaters, the safety valves have been restored to original state or states. Blind plates have been removed from steam and water systems.

(6)

Spring supports and hangers of steam and water pipeline are complete and in good order and pins have been removed.

(7)

All motorized valves and pneumatic valves on all steam and water pipeline have been tested and accepted.

(8)

The parties check jointly the boiler proper expansion systems to confirm that boiler expansion is not restrained and all expansion indicators are complete and reset to zero points.

(9)

Ladders, platforms and railing on boiler proper are complete and illuminated sufficiently and the boiler proper has been cleaned thoroughly.

(10) Drum level gauges have been installed, the level is indicated correctly. (11) Boiler water samplers and dosing systems have been installed, inspected and accepted correctly. (12) Feed water system, desuperheating water systems have been installed and insulated. All motorized valves and pneumatic valves have been tested. (13) All manholes and access doors on the boiler proper are complete and closed; 6.1.4

Soot Blower Systems (1)

Soot blowers and their pipeline in boiler proper have been installed and insulated.


6.1.5

6.1.7

6.1.8

6.2

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(2)

All motorized valves and pneumatic valves on steam supply pipeline for soot blowers have been installed and tested.

(3)

Soot blowers' local operation is safe and reliable. The blowers are ready for use at any time.

Compressed Air System (1)

6.1.6


Instrument& service air compressors have passed commissioning individually or as a subsystem and are ready for use.

Fire Protection System (1)

All fire fighting facilities are complete, fire water tests have been successfully completed and the systems are at standby state.

(2)

Fire fighting equipments have been equipped at boiler house, control room and place with fuel oil systems.

Industrial Water System (1)

Industrial water systems have been installed and hydrostatic tests have been successfully completed.

(2)

Commissioning of industrial water pumps and industrial water subsystems have been completed and pumps and systems are ready for operation.

Chemical Water System (1)

The chemical system is able to supply water continuously.

(2)

Commissioning of make-up water systems has been completed.


(2)

Cold commissioning of the boiler FSSS (fuel oil systems) has been completed 1)

Furnace blowing conditions have been checked and tested;

2)

Fuel oil OFT tests and interlock test (performed after the OFT test) have been completed;

3)

The fuel oil leak test has been completed;

4)

Combustion management systems for all oil guns have been tested.

Sequence control, interlock and protection test of each auxiliary device has been completed; 1)

Starting conditions, tripping conditions, program-controlled program-controlled shutdown of forced draft fans (A/B)

startup

and

2)

Starting conditions, tripping conditions, program-controlled program-controlled shutdown of water feed pump (A/B)

startup

and

(3)

Electric and I&Cs have been calibrated and are accurate.

(4)

For flue gas and air systems, measuring points of air temperature and pressure, furnace negative pressure, pressure switch, flue gas temperature and pressure of heating surface of different grade have been installed and are ready for operation.

(5)

For steam and water systems, measuring points of drum pressure, superheater pressure,



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steam temperature, feed water pressure, temperature and flow, steam flow and water level meter with electric contacts have been installed and tested and are ready for operation.

6.3

6.4

7.

(6)

For fuel oil system, measuring points of fuel oil pressure and temperature, flow meters, compressed air pressure have been installed, tested and are ready for operation.

(7)

Measuring points of auxiliary current, bearing temperature and vibration have been installed, tested and are ready for operation.

(8)

Commissioning of various protections, alarms and visual and audio signals has been completed and they are able to generate alarms properly.

Conditions Required for Environment (1)

The field is leveling; road is clear; cover on trenches are complete; wastes have be cleared.

(2)

Platforms, ladders, railings protecting sheets are complete; construction scaffold have be removed.

(3)

Site is sufficiently illuminated. Temporary illumination can be arranged if necessary.

(4)

Communication device is complete. Reliable communication equipment should be equipped.

Other Conditions Required (1)

The construction contractor, builder, Owner, Supervisor, Manufacturer and testing agency inspect the entire units thoroughly to confirm that the unit is ready for ignition. Problem found must be solved immediately, if any.

(2)

Preparation for trial operation has been completed and operators have been assigned, trained sufficiently and examined. Operation procedures and system drawings have been reviewed and approved and operating tools and log are available.

(3)

Chemical products and material required for commissioning have been prepared. Sufficient amount of chemical water, fuel oil and coal have been prepared according to the design requirements.

(4)

Necessary maintenance tools and materials are prepared.

(5)

A sound commissioning management organization has been established and the responsibilities have been clearly defined.

(6)

Commissioning material, tools, instrument and record lists have been prepared.

(7)

Instrument control, electric and engineering personnel are on site.


7.1

Responsibilities of Commissioning Contractor Preparation and revision of commissioning procedures; Preparation of commissioning plan;



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Preparation of instruments and equipment required for commissioning; Hold technical disclosure meeting for commissioning; Organize the commissioning work to be carried out by various parties; Give instructions to operators in the operation; Prepare commissioning report. 7.2

Responsibilities of Installation Contractor Be responsible for individual commissioning of equipment and provide relevant record and certificate of commissioning; Be responsible for inspection, maintenance and defect elimination of equipment under commissioning; Prepare maintenance tools and materials necessary for commissioning; Assist the commissioning contractor in the commissioning of subsystems; Be responsible for temporary coordination of local I&C components and connection terminals.

7.3

Responsibilities of Equipment Manufacturers Representative of manufacturer, if present on the site offering service, shall provide technical assistance during equipment commissioning.

7.4

Responsibilities of Plant Operator Prepare tools to be involved in operation; Prepare operation log and forms; Operate the system and equipment according to the operating procedures and the instructions of the commissioning personnel; Be responsible for patrol inspection, check, and normal maintenance of system and equipment; Be responsible for dealing with the accidents occurred in commissioning。

7.5

7.6



◆


◆


◆




◆


◆




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8.


8.1

Test of Valves

8.2

(1)

Test and accept motorized (solenoid) on off valve, and record data.

(2)

Test and accept pneumatic on off valve and record data.

(3)

Test and accept pneumatic adjustable valve and record data. SeeAppendix 5 and 6.

Interlock protection and alarm check (note: interlock protection test is subject to the results of logic discussion) (1)

Put the power supply of fans and water feed pump at testing position

(2)

Check the flowing items:

(3)

Start the fans or water feed pump on computer and the feedback on computer is right.

(4)

Stop the fans or water feed pump on computer and the feedback on computer is right.

(5)

Operation of the emergency button is reliable.

(6)

Interlock protection of start-up boiler system is as the following:

No.

Test item

1.

MFT Condition

(1)

Manual MFT (from the host computer or program control cabinet)

(2)

Stop forced draft fan s

(3)

Furnace pressure high (2 of 3 logic)

(4)

Furnace pressure low (2 of 3 logic)

(5)

Drum level high (1 of 2 logic) +150 mm

(6)

Drum level low (1 of 2 logic) -150 mm

(7)

Failure of fuel

(8)

Fuel pressure low (1.5MPa)

(9)

Drum pressure high; time delay 10 seconds (1.8 MPa)

(10)

Emergency flameout in whole furnace

2.

MFT reset

(1)

Reset button of host computer

(2)

Secondary reset button of program control cabinet

3.

Furnace blowing condition

(1)

Normal flame detector cooling air pressure lasts for 20 seconds

(2)

Air volume over than 30% and less than 40%

(3)

Put forced draft fan s into operation

Fixed value

Results

Remarks



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(4)

No flame on all flame detector

(5)

MFT condition does not exist

(6)

All dampers are open. (more than 30%)

(7)

All oil inlet valve are off.

(8)

Close master fuel oil valve in place

4.

Forced draft fan tripping condition (all conditions are met)

(1)

Furnace pressure high (2/3 logic)

(2)

MFT, close all oil valve in place, air volume over 30%, time delay 5 minutes.

(3)

No flame on oil burner.

(4)

Interlock in operation, forced draft fan trip and burner trip by interlock

5.

Start condition of forced draft fan: (all conditions are met)

(1)

All dampers are closed (less than 10%)

(2)

Send command to start fan

(3)

Power program control cabinet permit

6.

Stop condition of forced draft fan: (all conditions are met)

(1)

All dampers are closed (less than 10%)

(2)

Send command to stop fans or the tripping condition of fans meets or high current of fan

(3)

Forced draft fan interlock in operation; close master oil valves in place or the fan interlock is not in operation.

(4)

Power program control cabinet permit

7.

Start conditions of master oil inlet valves (all conditions are met)

(1)

Command to open oil valves

(2)

Close all oil inlet valves in place

(3)

No MFT

(4)

Oil inlet valves are not opened in place

8.

Close conditions of master oil inlet valves (all conditions are met)

(1)

Command to close oil valves or MFT

(2)

Oil inlet valves are not closed in place

9.

Start conditions of master oil return valves (all



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conditions are met) (1)

Command to open oil valves

(2)

All oil inlet valves are closed in place

(3)

No MFT

(4)

Oil return valves are not opened in place

10.

Close conditions of master oil return valves (all conditions are met)

(1)

Command to close oil valves or MFT

(2)

Oil return valves are not closed in place

11.

Permit to feed oil

(1)

Open fuel oil master valves in place

(2)

No MFT

(3)

Fuel oil pressure: not low, over 5 minutes (＞1.5,＜ 3.0)

(4)

No steam boiler OFT

(5)

No MFT command exists

(6)

Blowing is completed or the boiler is put into operation

(7)

Steam drum water level normal

12.

Boiler OFT (any condition is met)

(1)

All oil inlet valves, fuel oil valves are not closed in place, fuel oil pressure low

(2)

All oil inlet valves are not closed in place, fuel oil master valves are closed in place.

13．

Open of main steam valves (all conditions are met)

(1)

Send command to open valves

(2)

Power supply of main steam valves is not broken

(3)

State of program control

(4)

Main steam valves are not opened in place

14.

Main steam valves (all conditions are met)

(1)

Send command to close valves

(2)

Power supply of main steam valves is not broken

(3)


(4)

Main steam valves are not closed in place

15.

Open of steam release valves (all conditions are met)



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(1)


(2)

Power supply of steam release valves is not broken

(3)


(4)

Steam release valves are not closed in place

16.

Close of steam release valve (all conditions are met)

(1)

Send command to close velves

(2)


(3)


(4)

Steam release valves are not closed in place

17.

Open of emergency water release valves (all conditions are met)

(1)

Emergency water release valves are not opened in place

(2)

Drum level is high or manually open

(3)


(4)


18

Close of emergency water release valves (all conditions are met)

(1)

Emergency water release valves are not closed in place

(2)

Send command to close valves

(3)


(4)


19.

Open of steam valves for soot blowing (all conditions are met)

(1)


(2)

Power supply of steam valves for soot blowing is not broken

(3)


(4)

Steam valves for soot blowing are not opened in place

(5)

Overheated steam flow is over 70% BMCR and no MFT in boiler

20.

Close of steam valves for soot blowing (all conditions are met)

(1)

Send command to close valves or the soot blowing is completed.



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(2)

Power supply of steam valves for soot blowing is not broken

(3)


(4)

Steam valves for soot blowing are not closed in place.

(5)

Soot blower does not operate.

8.3

Drying

8.3.1

Purpose There is moisture in newly-built furnace wall. If putting it into operation directly without slow drying treatment to increase its strength, the moisture in furnace wall will generate some stress because of volume expansion caused by sudden evaporation, which may lead to crack, deformation and damage to furnace wall, even collapse if serious. So, drying under low burning according to requirements is a must before putting the boiler formally into operation.

8.3.2

Conditions required before drying (1)

Boiler proper and its auxiliary device have been installed, insulated and pass the air leakage test. The waste inside have been cleared and air leak test of furnance wall is qualfied.

(2)

Main steam pipeline system, water feed system have been installed and pass the hydraulic pressure test.

(3)

Brick laying, heat insulation and finishing of start-up boiler have been completed. Open every access door to dry the boiler naturally over 72 hours.

(4)

Device in drum has been completed. For water level meters, level mark is clear, position is correct, and illumination is sufficient to read the water level.

(5)

Relevant water releasing system have been installed. Water feed pump can feed water to boiler at any time.

(6)

Remote operation of I&C, sound, light and audio signal, and installed and checked protection device can be put into operation.

(7)

Feed demineralized water to the drum water level -30mm, and flush the water level meter clearly.

(8)

Cooling water system has been installed and pass the water test.

(9)

Water discharge system has been completed. And discharge is smooth.

(10) Daily oil tank has been installed. Oil tank has been cleared, and oil pipeline has been blown clearly. (11) Fuel oil system between oil tank and start-up boiler has been installed, insulated, blown throughly by compressed air, are with normal hydraulic pressure and ready for oil supply. (12) All auxiliary device, valves and dampers of boiler have been tagged. (13) Each rotatory machine has passed commissioning as a subsystem. (14) On and off of steam and water valves, flue gas and air dampers of boiler have been



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checked. Their movement is flexible, on-off direction and marks are correct. (15) Safety protection system of boiler has been tested. (16) Necessary illumination should be arranged for access road and equipments in commissioning field. Road is clear; cover on trenches and holes are complete. Communication is ready for clear liaison. (17) Steam trap on superheater is on to maintain normal pressure in drying. (18) Started oil guns of burner on boiler is well atomizedl, burn normally and pass service test. (19) The uniform commissioning organization of sufficient number of operators, maintenance personnel and security personnel shall be built. The operators shall be trained suitably and be familiar with the associated equipments and systems and operating methods and aware of commissioning measures, their own responsibilities and works to prevent incorrect operation. 8.3.3

Methods and Steps (1)

Close manhole of bottom drum, handhole of header, main steam valves, exhaust steam valves, blow down valves and drain cock of level meter.

(2)

Inject demineralized water, with temperature lower than 40℃, into boiler through economizer to the low water level of boiler (-20—-30mm), and close the water feed valve. When the water level in boiler is stable, observe whether the level decreases and check whether water leaks from the cover of the handholes, flange joint and blowdown valves. If not, bolts should be fastend and maintain low water level in boiler.(-20—-30mm)

(3)

Check whether oil tank has oil, oil pipeline leaks and oil and pipeline heaters are put into operation.

(4)

Start forced draft fans and adjust the damper regulator to blow the furnace.

(5)

Ignite with firewood. Control the combustion intensity by outlet flue gas temperature of furnace. Control the flue gas temperature strictly. On the first day, the rise does not exceed 50℃. Later, the rise does not exceed 80℃ every day. At last stage, highest temperature of flue gas does not exceed 160℃. Highest temperature does not last for over 24 h. During the drying, the water level of boiler should be maintained normal. Drying period should be controlled according to the degree of natural drying. During the drying, do not use hard fire, open exhaust steam valve to release air to keep no pressure in boiler, and heat slowly to avoid blow hot and cold to prevent the insulating layer of fire proof material from cracking and damage. Keep no pressure rising in drum, steam pressure for drying is not higher than 0.1MPa.

Note: Installation contractor should make temporary racks inside boiler to keep wood. 8.3.4

Safety Notice for Drying During the drying, fully open steam trap on superheater and exhaust steam valve at outlet of superheater. (1)

Flame should be controlled from light to strong and burn in the center uniformly to ensure uniform exotherm. Check furnace wall and expansion state of each part frequently, report the abnormal situation timely, if found.

(2)

During drying, strictly control the water level in drum, maintain it in normal scope, and



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feed water timely. (3)

Before drying, reserve discharge holes for moisture at proper position.

(4)

After drying, prepare temperature rise curve and relevant records.

8.4

Boiling out

8.4.1

Purpose Eliminate high temperature oxidation peel-roll, corrosion products, welding slag, silt, oil stain and other debris produced in rolling, processing, storage and installation. Generate protection layer in the inner wall to prevent corrosion, maintain the heating surface of boiler clean, increase the steam and water quality to prevent encrustment and corrosion, save fuel, extend life span and ensure safe and economic operation of boiler unit.

8.4.2

8.4.3

8.4.4

Scope and process of alkaline boil-out (1)

Scope: water screen system, lower drum, upper drum (the part under the flushing centerline of upper drum )

(2)

Washing: three steps are conducted for washing:

Flush with lots of water before washing;

Boil out the boiler with chemicals;

Flush the boiler with hot water after washing.

Conditions required before boiling out (1)

Hydraulic test has been completed and tested.

(2)

Commissioning of water feed pumps, induced draft fans and forced draft fans has been completed.

(3)

Chemicals for boiling out and containers for disolution have been prepared. Commissioning of chemical feed pump has been completed successfully.

(4)

Chemical water system can continuously supply enough demineralized water with sound quality. Flushing and recovery of dosing system have been completed and the system is ready for operation at any time.

(5)

Operator of power generator should be on duty and report state of water quality at any time.

(6)

Temporary indicator lights to indicate high, low and normal water level are equipped at control room the platform of drum, which have been prepared and accepted.

(7)

Operator and installation and maintenance people can operate and prepare necessary tools. Inspection and preparation for igntion should be done in advance according to Operation Specification before boil-out so as to make startup and ignition upon commands.

(8)

Systems have been tagged. Correct and clear marks is with various equipments, valves and flow direction of medium.

The following systems should be commissioned before boiling out. (1)

Flue Gas and Air System:

The inside has been cleared cleanly, checked and accepted.


(2)

(3)


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Dampers have been adjusted, checked and accepted.

Individual commissioning of forced draft fan has been passed.

Fuel Oil System

Hydraulic pressure test has been passed.

Blowing has been completed;

Fuel oil circulating is qualified;

Fire control device relevant to fuel oil have been tested and accepted.

Water Feed System

8-hour individual commissioning of water pump has been completed successfully;

Flushing of water feed pipeline has been completed successfully;

Relevant interlock test has been completed successfully.

(4)

Dosing system is ready for operation

(5)

Industrial water system is ready for operation

(6)

Ignition system of boiler

Atomization and service tests have been completed.

Ignition device has been tested normally.

(7)

All instruments of boiler have been assembled tested and are ready for operation.

(8)

Relevant valves of boiler have been assembled tested and accepted.

(9)

Water drainage systems are ready for use.

(10) Water feeding system are ready for use. (11) Blowdown system of boiler are ready for use. (12) All other systems that impact ignition of boiler 8.4.5

Method and Procedures (1)

Boiler working and hydraulic pressure test

1)

Check that the system meets the requirements for hydraulic pressure test

2)

Send water to boiler with water feed pump. In hydraulic test, ambient temperature should be over 5℃ above zero. Frost protection measures should be taken when temperature is under 5℃. Temperature of water used for hydraulic test should be over the ambient dewpoint temperature so as to prevent dew formation on the surface of boiler. The temperature should not be very high in order to prevent evaporation and high temperature difference. The temperature is usually within 20℃-70℃.

3)

Close the air vent when water comes out from them continuously. Boost pressure slowly at speed within 0.1—0.15MPa/min. Stop boosting pressure if abnormal situation is found.

4)

Boost pressure to 0.4MPa and fasten bolts of manholes, inspection holes and flanges.



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5)

Boosting pressure to 0.98MPa. Stop to check completely whether leakage or abnormal situation exists.

6)

If nothing is abnormal, boost pressure continuously to 1.29MPa and maintain for 20min to check whether leakage or abnormal situation exists.

7)

Hydraulic test is passed if:

No water drops and spray on metal wall or welding.

No residual deformation after the test.

No leakage at connection to economizer.

8)

After passing hydraulic test, release pressure and water. During the pressure reduction, clean I&C tubes, chemical sample tubes and water drainage pipes.

9)

Flush boiler with water.

(2)

Preparation of chemicals and dosing

1)

After the hydraulic test, feed water to 1/3, Stop and check system and isolate the water feed and drainage and blowdown system. Add chemicals slowly into the container while agitating. After the chemicals dissolve, feed the solution to the upper drum. Start the water feed pump of boiler to send water to the low level in drum.

2)

Dosing amount: sodium hydroxide (NaOH) 4 kg per m3 water; trisodium phosphate (Na3PO4) 4 kg per m3 water (calculated according to 100% purity quotient). Water volume is 22m3 (normal operating water volume in manufacturer's specification)

3)

Dosing Requirements:

Before cleaning, feed NaOH or Na3PO4 •12H2O slowly to the container at several times, and feed demineralized water (or soft water) to dissolve chemicals sufficiently for future use.

No solid chemicals can be fed directly into the boiler.

4)

After feeding chemicals, feed water to flush the container 2 to 3 times.

5)

After ignition, supervise water level in drum to maintain normal level. No full water is allowed. No water comes into superheater.

6)

Strictly control burning capacity in the first ignition and pressure boosting. Considering the expansion in the funnel of furnace wall and temperature difference between upper and lower wall of drum, pressure boosting rate can not be too fast, increasing to 0.2MPa-0.4MPa within 2 hours. Maintain the pressure and flush water level meter. Inform the installation contractor to tighten the screws in hot state. Boost the pressure to 0.80MPa within 5 to 6 hours. Maintain pressure at 0.8-1.0MPa for boiling out.

7)

Record expansion of each part under the following situation: Before and after feeding water, 0.4Mpa, 0.8MPa, 1.0MPa. Any part found to impact the expansion should be reported timely to stop increasing pressure. Continue boosting pressure after eliminate defect.

8)

Start timing when the pressure raises to 0.8MPa. Maintain pressure within 0.8-1.0MPa for 24 hours in boiling out. Steam drainage volume is 10%-15% of the rated evaporation.


9)


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After 240hour boiling out, maintain pressure of boiler, and each blowdown point discharge waste and change water. This moment, strictly supervise water level in drum and prohibit full and lack of water.

10) After feeding chemicals, take furnace water sample by chemical method to test alkalinity once every two hours. In the later stage of boiling out, test can be done once every one hour. 11) Normally shut down boiler after boiling out. Decrease pressure and drain water. 12) After the temperature decreases, open the manholes on upper and lower drum and lower header of water wall to clear away internal foreign matters. 8.4.6

Boiling precautions (1)

Agitate homogeneously when adding chemicals. Must not lift alkaline chemicals on shoulder or with hands. Operators should ware rubber overshoes, gloves and protection masks. Cold water resource and relevant chemicals should be arranged in place where prepare and add chemicals.

(2)

No water comes into superheater in boiling out. Strictly supervise the water level in drums and arrange experienced operators as far as possible to adjust feed water timely.

(3)

Closely watch the state of each rotary machine and expansion of boiler proper. Solve problems timely, if found.

(4)

In boiling out, one local level meter is set in drum, and one regulated pressure gauge is used. Assign people to watch the water level and inform water feeder timely.

(5)

Pipeline irrelevant to boiling out should be isolated completely. Prevent washing liquid in key system from getting into other systems to avoid accident.

(6)

In boiling out, blocked blowndown pipeline and valves should be cleared timely, if found.

(7)

In field, road should be clear, illumination should be sufficient, warning sign as "Washing! Dangerous! " etc. should be pasted, and guard rail and fence should be set.

(8)

In washing field, flushing water taps, soaps, towels and emergency medicine (3 L 0.2% boric solution, vaseline or scream to cure scald) and emergency car should be prepared, and also take necessary protection measures. If the alkali solution splashes onto skin or into eyes, flush with fresh water immediately, and then neutralize with 0.2% boric solution and flush with fresh water again. Ones seriously hurt should be sent to hospital for rescue immediately.

(9)

After boiling out, the manhole can be opened until the temperature of drum wall decrease to under 50℃ with monitoring of people. When the nuts could be loosen after 2 to 3 threads, use a wooden stick to unclench door of manhole (No people face the door directly). After the inside negative pressure disappears, open the door of manhole and assemble reticular close board on it.

(10) If no measures are mentioned for some conditions, execute the "Boiler Operation Specification". If accident occurs, deal with it according to Specification for Accident Handling. 8.5 Steam Purging 8.5.1

Purpose



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To ensure the safety and economy operation of the units, the inevitable welding slag, metal rust and other sundries in the boiler superheater and pipeline of steam system of newly assembled units shall be purged to the cleanest extent before the formal steam supply. 8.5.2

8.5.3

8.5.4

Scope

Boiler superheater system

Steam pipeline connecting start-up boiler to auxiliary steam header

Purging plan

Purge the boiler superheater system by energy storage (pressure decrease) method.

the Process: steam drum--> superheater--> main steam valve--> main steam pipeline--> temporary vent pipeline

Purge steam pipeline connecting start-up boiler to auxiliary steam header and boiler superheater system simultaneously.

Steam parameter for purging Open main steam valve when the drum pressure reached 0.5~0.6MPa. After fully open main control valve, drum pressure decreases to 0.4~0.5MPa. At that time, close main steam valve.

8.5.5

Quality standard According to the new "Technical Code for Erection and Acceptance of Electric Power Construction (1996 Edition)", while ensuring the purging factor larger than one, the purging work is qualified as the matter, maximum particle diameter on the target board no more than 0.8mm and number of macroscopic spot no more than 8, happens for twice continuously.

8.5.6

8.5.7

Temporary devices (1)

The temporary pipeline shall be connected in proper place before plant-service steam header and be led to safe place for steam exhausting with outlet directed to open space. Target board shall be installed in the suitable place near regular pipeline. In condition that the quality of purging is guaranteed, minimize the length of the pipe, elbows and joints to reduce the resistance for the system.

(2)

Temporary purging pipeline shall be equipped with solid and reliable supports and hangers and consider the thermal expansion of the pipeline and steam counterforce by purging.

(3)

Same-diameter short pipe shall be connected instead of main steam flow orifice plate until the purging work is finished.

Precondition for ignition (1)

Systems return to normal after boiling and cleanup of upper and lower drum and sub-header of water wall.

(2)

Main boiler and auxiliary equipments have been installed and insulated. Plateform, handrail and boarding are complete.

(3)

All facilities which affect the expansion have been removed.

(4)

Sufficient illumination is around the boiler proper and auxiliary units.

(5)

Installation of water level meter in drum shall meet the requirements. The local water level meters are accurate and remote water level meters are regulated and can be put into



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use for purging. (6)

Sundries shall be cleared up inside the furnace and funnel.

(7)

Water charging and supply system shall meet the requirement and be ready to use.

(8)

Purging control valve have been adjusted and temporary pipeline have been completed according to requirement.

(9)

In boiler house, discharge systems of washing water and overflow have been installed as per design requirements.

(10) Dosing, sampling, blowdown systems have been installed as per design requirements. (11) Chemical water treatment system can guarantee to supply qualified demineralized water. (12) Purging field is tidy, road is clear, trench covers are complete, and scaffolding have been removed for convenient operation. Operating floor has been completed basically without any vulnerability such as voids etc. (13) The utilities system can guarantee the safety and stability of production, construction and commissioning. (14) Preparation work has been done for commissioning. Operators, trained and tested, are qualified. Operation specifications and system diagram have been approved. Operating tools are fully equipped and commissioning log is prepared. (15) A sound commissioning management organization has been established, the responsibilities and liaison system have been clearly defined. Personnel for adjustment, maintenance and operation are on board. Commissioning measures have been approved and technical clarification has been performed. (16) Chemicals materials, chemical water and fuel oil for commissioning are ready. (17) Fire-fighting equipments and facilities in field shall meet the requirements. (18) The Installation Contractor, Operation Contractor, Owner, Supervisor, Contractor and Commissioning Contractor inspect the entire units thoroughly to confirm that the unit is ready for ignition. Problem found must be solved immediately, if any. 8.5.8

8.5.9

Tests before ignition (1)

The system valves and dampers for purging shall be inspected completely by operators to meet the following requirements: flexible operation; on-off direction accords with the indication; and remote panel conforms with local one.

(2)

Test for interlock protection

Preparation before ignition (1)

Start up water feed pump until the water level reaches about -30mm in the drum.

(2)

Preparation before ignition should been made as per specifications when receiving ignition signal.

Notify the electric control room to feed the rotary machine, electric dampers and electrically operated steam and water valves to be used.

Heating control room feeds the panels and instruments to be used.

Put cooling water system into use.


8.5.11


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Ignition is implemented as per specifications.

Purging process (1)

Ignite and increase the pressure once receiving ignition signal. When the pressure reaches to 0.2MPa, steam pipeline should be warmed up. After that, trial purging is started and check if the system expansion and stress state are normal when the pressure is up to 0.3MPa. If normal, boost pressure continuously to 0.4MPa~0.5MPa for next purging until the target board is basically qualified. Then shut down and cool the boiler for 12hr and ignite the boiler and boost the pressure again to purge until the target board is qualified.

(2)

After purging, to boost pressure for leak test and safety valves adjustment or to shut down for system recovery is subject to the site conditions.

Safety precaution and instruction (1)

Keep combustion as stable as possible when purging.

(2)

The drum water level control to avoid severe water shortage or overfall is of the greatest significance during purging period. As the control valve opens, the steam pressure decreases sharply, which causes great rise of drum water level. Actually, it is false appearance, and the water supply shall be increased suitably rather than being decreased. For the reason that the drum water level declines greatly even it is invisible when the control valve is closed, increase the water supply to maintain a visible level when closing the valve. When the water level starts to rise again, reduce the water supply promptly to avoid rising too high. To prevent steam from bearing lots of water, the drum water level shall be maintained around -50mm before opening the control valve in purging.

(3)

No flammable and explosive materials near purging pipeline. No people in area 20m around steam outlet. Set guard line and assign persons to be on duty.

(4)

Make sure that everyone has left before opening the control valve, especially when changing the target board. Person unrelated shall keep away from purging pipeline

(5)

Pipeline shall be warmed up completely before purging. Trial purging, under the pressure 50%~75% of the regular pressure shall be conducted once or twice to inspect the conditions of support, expansion and leakage of the temporary system and learn the control method of water feed flow gradually. Steam trap on main steam pipeline shall be partially opened while the other is closed during normal purging work.

(6)

A target board shall be put in the pipeline to check the dirtiness of pipeline and the reliability of board in the first purging.

(7)

All rotary machines shall be monitored by relevant personnel.

(8)

Operation should be conducted in a manner of unity of command. Shut down purging in case of emergency, and handle accident according to Accident Management Procedure.

(9)

The parts unable to be purged by steam shall be cleaned mechanically and manually. Safety measures shall be considered to prevent the dirt from recovered welding joint.

(10) 20 pieces of target board, made of aluminum and polished, should be prepared. Target boar size: no less than 8% of the inner diameter of discharging pipeline in width; and equal to the inner diameter in length.


8.6

Steam Tightness Test

8.6.1

Purpose:


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To guarantee the safety operation of the units in future, the steam tightness test, under the operating pressure at hot state, is to completely inspect the boiler's heating surface, the steam & water pipeline, steam header, flanges. welded junction, expansion system and load-carrying capability, displacement and the extension of fixing apparatus or spring supports and hangers. 8.6.2

8.6.3

8.6.4

8.6.5

Test Content: (1)

Close the main motorized steam valve at the boiler outlet; the pressure boosting rate can be controlled by the adjustment of fuel oil pressure or the exhaust steam valve. When pressure rises to 1.29MPa and is at steady state, people specially assigned shall check the tightness of the boiler proper, auxiliary device and the steam and water pipelines involved.

(2)

Inspection the tightness of welded joints and flanges of the boiler.

(3)

Inspection tightness of all the steam and water valves of the boiler proper system.

(4)

For steam and water pipeline of the boiler, check its expansion condition, check whether the load-carrying capability, the displacement and the extension of its supports, hangers and spring hangers are normal, and check whether any barriers impact the expansion.

Testing conditions: (1)

Purging has been completed.

(2)

Areas inside and outside boiler is cleaned. Road is clear.

(3)

No expansion barriers on boiler proper. Expansion indicator has been installed and regulated to zero.

(4)

All inspection holes and manholes have been closed.

(5)

Tests and inspections before ignition have been completed.

Test Procedure： (1)

Timely adjust combustion intensity and open rate of steam trap. Control temperature and pressure rise rate according to Operation Specification.

(2)

Record expansion value at the following conditions: before and after water feed, 0.3–0.4Mpa, 1.0MPa, 1.29MPa.

(3)

Start steam tightness test when pressure of main steam rise to 1.29MPa.

Safety Precautions: (1)

Strictly control increasing rate of temperature and pressure to ensure sufficient expansion of each heating part of boiler proper.

(2)

Check the expansion state of each heated part in pressure boosting process. Report problems if found. Stop increasing temperature and pressure, if necessary, to take measures to eliminate a hidden danger. Then continue the process.

(3)

Operation should be conducted in a manner of unity of command. Strictly follow orders and prevent personal injury and damage to equipment. All operating personnel participating commissioning shall strictly follow Safety Regulations and related safety provisions at site, thus to ensure safe and reliable commissioning.



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(4)

If equipment damage or personal injury may occur, stop works immediately and shut down the unit if necessary, and then analyze causes and take corrective measures;

(5)

During entire commissioning, personnel of various discplines shall be in place, thus to ensure equipment operation safety.

8.7

Safety valve setting

8.7.1

Purpose: Being the primary safety devices for the boiler, safety valves of drum and superheater shall be adjusted to act accurately and reliably before commissioning to ensure the safe operation of the boiler unit.

8.7.2

Setting parameter: Refer to attached table.

8.7.3

Preparation before tests

8.7.4

8.7.5

(1)

Safety valves have been installed and checked, which accords with installation requirements.

(2)

Standard pressure gauges, provided by the installation contractor to adjust the safety valves, have been installed (0～5MPa per one, above grade 0.5).

(3)

Safety valves platform is clean. Road is clear. Illumination is sufficient.

(4)

Adjustment tools, communication tools and record lists are prepared.

Setting procedure (1)

Start steam discharge test when pressure rise to 0.8MPa-0.9MPa. Check the steam discharge and action of safety valves. If no problems found, continue boosting pressure to the setting pressure needed for setting. The setting of safety valves is conducted before the setting of safety valve of superheater.

(2)

Decrease pressure after the setting of safety valves. Start the setting of safety valves on the superheater.

(3)

If the trial actuation of the safety valve is not qualified for the first time, decrease pressure and adjust it again. Then increase pressure to test the trial actuation until it is qualified.

Safety Precautions: (1)

During the adjustment of safety valve, operators and safety valve adjustors should act according to the unified command of commissioning personnel so as to ensure personal and equipment safety. .

(2)

Participants should keep their post according to work division and take records of operation, adjustment and check.

(3)

During the adjustment, enough platform and railings should be set around safety valves; illumination is sufficient.

(4)

Before setting, release the drum water level protection, in case the false level caused by take-off of safety valve starts the protective action of boiler.

(5)

During pressure boosting, assign people to check the tightness and expansion of boiler. Report and solve problems found to impact the increasing of pressure and temperature timely.


(6)


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During the adjustment, operator is responsible to maintain the stable working state of unit, especially the stable pressure. At the moment the safety valves discharge steam, drum water level changes greatly. So, when adjusting the safety valves, drum water level should be lower than the normal level. Adjust the water supply to control the drum water level properly.

(7) Decrease the pressure to 75% of the actuation pressure before adjusting the safety valves. Experienced operator with protection masks and heating-insulated gloves adjust the safety valves, and others should be kept away from the field. (8)

During the adjustment, adjust the weight of safety valves on drums. Remove top cover of safety valves on superheater, unscrew or wind up spring to reach the set actuation pressure. Then tighten fastening screw, assemble the top cover and tighten the hexagon screw.

(9)

Do not hit any parts on the safety valve. Lift handle directly to open the safety valve.

(10) After the adjustment of safety valve, all externally adjusted parts should be marked, fastened, sealed, recorded and certificated before put into operation. Attached List: Name/Type

Design value Popping Return Pressure Pressure（MPa）（MPa）

Drum Safety valve A48Y-25 Super heater Safety valve SA48Y-25

Actual setting value Popping Pressure Return Pressure Remarks （MPa）（MPa）

1.43

1.33-1.37

4-7%

1.30

1.21-1.25

4-7%

Remarks: Actuation value of safety valve is from the Manufacturer's Information. 8.8

Load commissioning

8.8.1

Test purpose: Load commissioning is main process of unit commissioning. Concerning to the safety, quality and project period of unit commissioning, load commissioning is a comprehensive performance evaluation of the unit and complete check and inspection of the sub-system commissioning at the early stage.

8.8.2

Conditions required before load commissioning (1)

Drying and boiling out, steam purging, tightness test, safety valve setting of start-up boiler have been completed.

(2)

All temporary system used in sub system have been removed.

(3)

All defects found in the subsystem commissioning have been eliminated.

(4)

Chemical water system is complete to supply qualified demineralized water at any time.

(5)

Plant-service power system is complete to cut and supply power according to commissioning requirements at any time.

(6)

Illumination and communication system is complete to communicate at any time. Fire control equipments are equipped.



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(7)

In commissioning field, road is clear, illumination is sufficient, emergency illumination is reliable.

(8)

Boiler chemical feed, sampling, blowdown and drainage, air vent system have been installed and insulated.

(9)

All steam and water valves and dampers for boiler have been installed and tested. On-site open rate is the same as that shown in center control room.

(10) Confirm that the following systems have been installed and can be put into operation.

Boiler air and flue gas system;

Water feed system;

Fuel oil system;

Industry water system;

Chemical feed, sampling system;

Drainage system;

Water supply, drainage and fire control system;

Main steam system and its desuperheating water

(10) All on-site instruments and instruments on operation platform and panels have been installed and calibrated, and can be put into use. (11) All interlock protection loop has been installed. After static test, all interlock, protection and alarm value have been set according to requirements. Visual and audio system has been adjusted. (12) Boiler expansion indicator has been installed according to design requirements. Expansion barriers have been eliminated and expansion indicator has been regulated to zero. (13) Observation holes, manhole door and inspection holes have been closed. Explosion door is complete. (14) Prepare sufficient fuel oil for commissioning. (15) Prepare sufficient chemical water and chemicals. (16) Production preparation has been made. Operators passing training are on duty. (17) Organization is complete and job division is clear. (18) Constructor organizes maintenance team and prepare materials and tools for maintenance. (19) Operation measures should be approved and clarified under the direction of commissioning command party. Commissioning, operation, maintenance personnel is on duty. (20) Marks of equipment and main pipeline are complete and meet requirements. Tags on system equipment and valves are complete. (21) Auxiliary header on the steam supply side has been installed and insulated and are ready for steam.


8.8.3


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Commissioning period (1)

Non-load period After the commissioning of all subsystem of start-up boiler, restore the temporary system and steam can be sent to auxiliary header. The warm-up of pipeline before supplying steam to the auxiliary header is the non-load commissioning.

(2)

Load period After the start-up boiler supplies steam to the auxiliary header, adjust the burning capacity according to steam consumption of users, and adjust the boiler load to keep pressure steady.

8.8.4

Commissioning Procedure (1)

Non-load procedure

1)

Water feed Water feed time: winter≥2 hrs; summer≥1 hrs. Feed water temperature <40℃. Before feeding water, close blowdown valves and open air vent and exhaust steam valve to release air in boiler. Start water feed pump to inject soft water to the boiler through economizer. Stop water feed pump when the water level is higher than the low alarm. After the level is stable, check whether the level decreases. If so, check and deal with it.

2)

Work before ignition: check the conditions required

3)

Ignition of boiler.

4)

Start induced draft fan and forced draft fan and set ventilation tunnel. Adjust the furnace pressure to -20～-50Pa.

Adjust the ventilation quantity to 30%--40% to blowing the furnace.

Confirm that the ignition requirements are met, then start the main oil valve and prepare ignition.

After send the ignition signal, ignite the boiler.

Pressure boosting

After ignition, adjust the oil pressure of oil gun according to temperature and pressure rise curve for cold start-up. Increase pressure and temperature of boiler. At the early stage of pressure boosting, adopt low burning. When boosting the pressure, temperature can not rise too fast to avoid overlarge heat stress caused by uneven heating.

After the pressure rises, watch the level in boiler. Level rises because of heating. If it exceeds the highest level, start blowdown.

When saturated vapour is generated in the drum or drum pressure reaches 0.1MPa, increase combustion, close exhaust steam valve and flush water level meter and elbow of pressure gauge at the same time.

When drum pressure rise to 0.1MPa, close corresponding air vent.

Drum pressure rises to 0.2--0.4MPa and operation is steady. Check whether the boiler is abnormal. Ask installation contractor to tighten screws in hot state. Ask heating engineering team to flush instrument pipe and regulate the level meter.



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Ask the chemical team to flush the sample tube.

5)

When pressure increases gradually, note whether each part makes special sound. If so, check the state immediately. Shut down furnace to check, if necessary. Start operation after lifting failure.

Continue boosting pressure. When drum pressure reaches the required value, stop burning.

Open the valve of superheat steam outlet to put water feed system into operation, adjust combustion, open desuperheating water, and supply steam formally. Continuous bolwdown should be carried out during steam supply.

Formal steam supply

When steam pressure reaches working pressure 1.29MPa, supply steam. Before supplying steam, maintain low drum water level, sufficient pipeline warm-up and steady combustion in furnace,

Desuperheating water is used to adjust the temperature of superheat steam. When the temperature of superheater steam is higher than the required value, increase the desuperheat water to decrease the temperature of superheat steam by motorized control valve of desuperheating system. When the temperature of superheater steam is lower than the required value, decrease the desuperheat water to increase the temperature of superheat steam. Adjust the temperature of superheat steam within 300±5℃.

(2)

Load period

1)

Adjust the burning capacity according to steam consumption of users and fuel oil pressure. Maintain steady pressure, combustion, water level of boiler. Keep steam temperature within regulated scope. The oil temperance and pressure meet the requirements.

2)

Start thermal adjustment of automatic control system at proper time, according to load of boiler.

(3)

Automatic adjustment of drum level

Automatic adjustment of furnace pressure

Automatic adjustment of combustion

Automatic adjustment of desuperheating water

Normal operation and maintenance

When boiler is in operation, continue feeding water to keep water level within normal scope. Water level meter should be flushed at least once each shift.

Note the combustion state frequently. Maintain reasonable air distribution for good combustion. Keep the furnace pressure between-250—-50Pa

Supervise and maintain the pressure and temperature of overheat steam, and make it within normal scope。

Note the boiler proper and gas and air flue, and make pressure, gas temperature and wall temperature of them within normal scope.

Check the reliability of valve action frequently. Patrol equipment and system



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frequently. Report or handle with abnormal situation, if found.

(4)

(5)

8.8.5

Supervise the quality of feed boiler water. Periodical and continuous blowdown should be executed after receiving the notification of chemical team.

Operator should take records of boiler operation parameter hourly。

Normal shut down

Reduce fuel and corresponding air volume gradually to weaken the boiler capacity. With the decreasing of the load, reduce water to maintain normal level in drum。

When the steam supply is cut off, close the boiler outlet motorized valve. If the pressure continues boosting, steam release and water fed should be strengthened.

After pressing the shut down button, the burner will turn off oil-gas solenoid valve automatically. After five minutes, blow the furnace, and the boiler will shut down automatically. After flameout, check and close flue baffle and manual valves of fuel oil system. Stop the oil pump. Stop water feed pump when water is stopped.

Before the drum pressure decreases to the atmosphere, temperature of flue gas and air system and auxiliary device must be supervised continuously.

Occasions for Emergency Shut Down

Pressure over the specified value

Low low water level in drum, and level can't be observed

Water supply device malfunction, fail to feed normally

All level meters malfunction

All safety valve malfunction

Cracks on boiler, blurts of water wall tube, overheat steam pipe and economizer pipe burst and

damage of boiler wall threats the safe operation of boiler severely

Complete trial operation record： For main parameter in trial operation, see the Appendix 2.

9.

Safety Measures

9.1


9.1.1


9.1.2


9.1.3


9.1.4

All professional staffs shall be on respective duties during the whole commissioning to



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guarantee the safe operation of equipments. 9.2


Rotary machine In adjustment or test, people may be injured by the rotary machine. So, work carefully to avoid touching the rotary parts with hands or tools.

Misapplication or non-wearing of helmet In adjustment or test, injury or death may be caused by object strike. Once in field, wear helmet and safety belts. Check and eliminate the dangerous thing which may fall from upper and surrounding area of operation.

Burned by damage of temporary purging pipeline. All temporary pipeline should be insulated. Before purging, pipeline should be warmed sufficiently to avoid water hammer accident. Perform trial purging several times under pressure 40%—50% and 70%—80% of the purging pressure.

Steam burn and noise pollution at purging steam outlet Assign people to arrange safety isolation measures strictly at purging steam outlet.

Injured by high temperature flue gas of observation hole and manhole door Close all observation hole and manhole door. Increase pressure properly before fire observation on site. In fire observation, stand on the side of the hole, and make metal preparation for evacuation at any time.

9.3


Abnormal operation If it is found that an operating equipment emits abnormal sound or has other abnormal condition, and such problem may not be eliminated, stop such equipment and report to the control rooms immediately。

Fuel oil system fire Strict fire-fighting measures should be set during commissioning. No combustibles and explosives materials are laid around fuel oil system. Sufficient fire control equipment is equipped on site.

Bad combustion results in flameout; accumulative oil make explosive flame Fire failure protection must be arranged. Strengthen combustion adjustment to ensure good combustion. If atomization of oil gun is poor, must clean it manually. After flameout in furnace, 5-minute purging must be conducted before re-ignition.

Equipment damages and people injuries result from over temperature or pressure Feed fuel slowly and steadily. Strengthen the monitoring of flue temperature in different points. In case that burning rate is out of control, shut down boiler immediately. Assume the pressure-releasing accident in advance. Strictly control the superheater outlet pressure no more than 1.25MP and the steam temperature no more that 450℃. Otherwise, weaken burning or release pressure. Over pressure operation is forbidden, especially before safety valves are adjusted and put into operation.

Instrument damages result from burning of accumulated oil at tail end



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Strenthen combustion adjustment to ensure good combustion; blow the dust on the heating surface at tail end regularly. After shutting down, normal water lever must be maintained and the system must be purged heavily before close; Meanwhile, strengthen the monitoring of the flue temperature at tail end, deal with problems timely, if found. Irregularly check soot in the end funnel and blow away regularly. Boiler should be purged with heavy blow before and after restart. Assign people to monitor here, and temporary fire-fighting equipment fire water system are available.

10.

Appendix


10.1 No. 1

（1）

（2）


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Appendix 1 Commissioning Condition Checklist Items

Requirements

Result

Conditions for trial commissioning

Flue gas &air systems

Fuel Oil System

（3） Boiler Proper

Boiler air pressure test has been successfully completed. Each air leakage has been treated.

□Yes □No

Boiler proper and flue gas duct have been assembled and insulated.

□Yes □No

Individual commissioning and subsystem commissioning of forced draft fans have been completed.

□Yes □No

All damper flue gas and air systems have been inspected, adjusted and accepted.

□Yes □No

System has been assembled and individual commissioning has been completed.

□Yes □No

System hydraulic pressure test and water flushing has been completed successfully.

□Yes □No

Compressed air pipeline and valves for blowing should be assembled and tested.

□Yes □No

All motorized valves and pneumatic valves for systems have been tested and accepted.

□Yes □No

The burner has been assembled and tested.

□Yes □No

All interlock protection simulation test have been successfully completed

□Yes □No

The ON/OFF tests for all oil guns and high-energy igniters have been successfully completed.

□Yes □No

Cold commissioning for all flame detectors have been completed.

□Yes □No

Boiler proper have been installed, insulated and accepted;

□Yes □No

Individual commissioning and interlock protection test for water feed pump have been completed.

□Yes □No

Hydrostatic tests of the boilers have been successfully completed;

□Yes □No

The drain, vent, blowdown and nitrogen charging systems of the boilers have been installed and insulated. All motorized valves have been tested and accepted.

□Yes □No

Verifie d by

Rem arks


（4）

（5）

（6）

Soot blower

Compressed Air System Fire Control System


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After hydrostatic tests, temporary valve plugs have been removed from all safety valves of the drums and superheaters, the safety valves have been restored to original state or states. Blind plates have been removed from steam and water systems.

□Yes □No

Spring supports and hangers of steam and water pipeline are complete and in good order and pins have been removed.

□Yes □No

All motorized valves and pneumatic valves on all steam and water pipeline have been tested and accepted.

□Yes □No

The parties check jointly the boiler proper expansion systems to confirm that boiler expansion is not restrained and all expansion indicators are complete and reset to zero points.

□Yes □No

Ladders, platforms and railing on boiler proper are complete and illuminated sufficiently and the boiler proper has been cleaned thoroughly.

□Yes □No

Drum level gauges have been installed, the level is indicated correctly.

□Yes □No

Boiler water samplers and dosing systems have been installed, inspected and accepted correctly.

□Yes □No

Feed water system, desuperheating water systems have been installed and insulated. All motorized valves and pneumatic valves have been tested.

□Yes □No

All manholes and access doors on the boiler proper are complete and closed;

□Yes □No

Soot blowers and their pipeline in boiler proper have been installed and insulated

□Yes □No

All motorized valves and pneumatic valves on steam supply pipeline for soot blowers have been installed and tested.

□Yes □No

Soot blowers' local operation is safe and reliable. The blowers are ready for use at any time.

□Yes □No

Instrument& service air compressors have passed commissioning individually or as a subsystem and are ready for use.

□Yes □No

All fire fighting facilities are complete, fire water tests have been successfully completed and the systems are at standby state.

□Yes □No


Industrial （7） Water System

（8）

2

Chemical Water System

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Fire fighting equipments have been equipped at Boiler House, Control Room and place with Fuel Oil Systems.

□Yes □No

Industrial water systems have been installed and hydrostatic tests have been successfully completed.

□Yes □No

Commissioning of industrial water pumps and industrial water subsystems have been completed and pumps and systems are ready for operation.

□Yes □No

The chemical system is able to supply water continuously.

□Yes □No

Commissioning of make-up water systems has been completed.

□Yes □No

Electric and Heating Control Test

Cold commissionin g of the boiler （1） FSSS (fuel oil systems) has been completed

Sequence control, and protection test （2） of each auxiliary device

（3）


Electric and I&C

Furnace blowing test have been completed

□Yes □No

Fuel oil OFT tests and interlock test (performed after the OFT test) have been completed;

□Yes □No

The fuel oil leak test has been completed;

□Yes □No

Combustion management systems for all oil guns have been tested;

□Yes □No

Starting conditions, tripping conditions, program-controlled startup and program-controlled shutdown of forced draft fans (A/B)

□Yes □No

Starting conditions, tripping conditions, program-controlled startup and program-controlled shutdown of water feed pump (A/B)

□Yes □No

For flue gas and air systems, measuring points of air temperature and pressure, furnace negative pressure, pressure switch, flue gas temperature and pressure of heating surface of different grade have been installed and are ready for operation.

□Yes □No

For steam and water systems, measuring points of drum pressure, superheater pressure, steam temperature, feed water pressure, temperature and flow, steam flow and water level meter with electric contacts have been installed and tested and are ready for operation.

□Yes □No

For fuel oil system, measuring points of fuel oil pressure and temperature, flow meters, compressed air pressure have been installed,

□Yes □No



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tested and are ready for operation. Measuring points of auxiliary current, bearing temperature and vibration have been installed, tested and are ready for operation. Various protections, （4） alarms and visual and audio signals 3 （1）

Field, road and cover

Temporary illumination

Communicatio （4） n equipments 4

It has been tested and they are able to alarm properly. □Yes □No

Conditions for Environment

Construction （2） scaffold

（3）

□Yes □No

wastes have be cleared. complete have be removed. can be arranged if necessary complete Reliable

□Yes □No

□Yes □No

□Yes □No □Yes □No

Other conditions

The construction contractor, Owner, （1） Supervisor, Manufacturer and testing agency

Inspect the entire units thoroughly to confirm that the unit is ready for ignition. Problem found must be solved immediately

（2） Operation procedures

Pass review, operation tools and logs are well prepared

（3） Chemical product, material, chemical water and fuel oil

ready have been prepared according to the design requirements.

（4） Overhaul tools and materials

ready

（5） A sound commissionin g management organization

established and the responsibilities have been clearly defined.

（6） Commissionin g material, tools,

ready

□Yes □No

□Yes □No

□Yes □No

□Yes □No

□Yes □No

□Yes □No



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instrument and record lists （7） Instrument control, electric and engineering personnel

on site □Yes □No


Contractor:

Date:

Date:


Dongfang Electric:

Date:

Date:


10.2


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Appendix 2 Format for Trial Run Record Content

Unit

Data

Content

Unit

Main steam pressure

MPa

Supply oil pressure

MPa

Main steam temperature

℃

Open rate of #1 oil return valve

%

Main steam flow

T/h

Open rate of #2 oil return valve

%

Drum pressure

MPa

Open rate of #1 damper

%

Water level in drum

mm

Open rate of #2 damper

%

Feed water flow

T/h

Current consumption by forced draft fan

A

Feed water pressure

MPa

Open rate of damper of forced draft fan

%

Temp. of feed water

℃

Outlet pressure of forced draft fan

KPa

T/h

Furnace pressure

PA

Water level in deaerator

mm

Temperature of flue gas at outlet of superheater

℃

Temperature of flue gas at outlet convection bank

℃

Desuperheatering flow

water

Data


10.3


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Appendix 3 Pressure boosting curve-boiling out

Time （h）

hot flushing

56 52 48 44

36

Maintain 0.8~1.0 MPa in boiling out

Pressure boosting curve-boiling out

40

32 28 24 20 16 12

Pressure（MPa）

8 4

0 1

1

1 0 0 0

0 0 0

0. 0. 0


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Appendix 4 Pipeline Blowing System Diagram

To atmosphere

Target board

M control valve

main steam pipe

superheater

Upper drum

Pipeline Blowing System Diagram

10.4


PLTU 1 Jatim-Pacitan（2×315MW） Project Procedure of Start-up Boiler

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10.5

Appendix 5 Check list of dampers

Dampers commissioning record KKS code

Remote


Direction


Date:

Name Emergency water drain valve on drum Main steam valve Exhaust steam valve Steam valve for soot blowing Steam trap for soot blowing Master oil inlet valve Master oil return valve #1 oil inlet valve #1 oil return valve #2 oil inlet valve #2 oil return valve #1 oil inlet blowdown valve #1 oil return blowdown valve #2 oil inlet blowdown valve #2 oil return blowdown valve #1 oil gun #2 oil gun


Date:

Date:

Dongfang Electric:

Date:

Feedback

Operating time On Off (Open) (Close)

Date

Result

Signatu re

Remark s

PLTU 1 Jatim-Pacitan（2×315MW） Project Procedure of Start-up Boiler

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10.6 Appendix 6 Check List of Control Dampers Commissioning record of control dampers KKS code

Feedback of ascending and descending instruction values

Name

0%

25%

50%

75%

100%

Control damper of forced draft fan Control damper of #1 burner Control damper of #2 burner Pressure adjustable valve of deaerator Level adjustable valve of deaerator Water feed adjustable valve Desuperheatering water adjustable valve #1 oil valve

return

adjustable

#2 oil valve

return

adjustable


Date:

Date:


Dongfang Electric:

Date:

Date:

75%

50%

25%

0%

Date

Result

Signatu re

Remar ks



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-M-01-HLB-002 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI


Check Design Scale


DETAIL DESIGN STAGE

Procedure of FDF System N/A

DWG No.

SCCTI-TS-GL-CS-007-200 9A

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A


Procedure of Forced Draft Fan System

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PURPOSE ........................................................................................................................................... 3

2.

SCOPE ................................................................................................................................................ 3

3.


4.


5.


6.


7.


8.


9.

SAFETY MEASURES..................................................................................................................... 13

10.

9.1


9.2


9.3

Equipment Risk and Preventative Measures ................................................... 14 APPENDIX ............................................................................................................................... 14

Appendix 1

Commissioning Condition Checklist....................................................... 15

Appendix 2

Trial Operation Parameters of FDF and Its System................................. 17

Appendix 3

Control Damper Commissioning Record of FDF and Its System ........... 19

Appendix 4 FDF Dampers Commissioning Record.................................................... 24



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1.

Purpose

1.1

Instruct and specify the commissioning for the equipment and system to guarantee the safe and normal operation.

1.2

Check the reliability of electric and I&C interlock protection and signal device。

1.3


2.

Scope This procedure is applicable to the subsystem commissioning of the FDF system, including such items as verification of the air damper, interlock protection test, application of the system commissioning and dynamic adjustment.

3.

Preparation Basis

3.1

Manual for the installation, operation and maintenance of FDF

3.2

Flue-gas and air system diagram of the boiler

3.3

Control logic diagram of FDF

4.


4.1

Two operating FDFs with air output adjusted by moving blade

4.1

Technical parameters of FDF Model of FDF ASN-2240/1400

Adjustable axial -flow moving blade

Name and parameters

Unit

TB

BMCR

TMCR

Flow at inlet of FDF

m3/s

138.05

115.04

100.07

Inlet temperature

℃

30

30

30

Medium density

Kg/ m3

1.088

1.088

1.088

Total pressure of FDF

PA

4055.7

2896.1

2558

Shaft power of FDF

KW

692.8

395.3

312

%

84.5

85

85

r/min

1490

1490

1490

Total pressure efficiency of FDF Rotary speed 4.3

Motor parameters Model of motor Rated power

YKK560-6 800 KW

Rated voltage Rated speed

5.


5.1

Walkie talkie;

5.2


6300V 1490 r/min



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5.3

Tachometer;

5.4

Clip-on ammeter.

6.

Prerequisite for Commissioning Before formally beginning commissioning job system by system, commissioning persons should conduct comprehensive checks on conditions that should be available for commissioning of this system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and make well the records.

6.1

Environmental conditions

6.1.1

The site within the scope of system should be level, the road should be clear,, the trench cover plate is complete, and the environment is clean, free of sundries.

6.1.2


6.1.3

The lighting shall be sufficient, and temporary lighting shall be installed if necessary.

6. 1.4

The reliable communication devices shall be provided on the site.

6.1.5

The fire-fighting equipments shall be sufficient on the site

6.2


6.2.1

Completion of installation for all devices, piping as well as the subsidiary systems and heat insulation for FDF system

6.2.2

Qualified single commissioning of FDF

6.2.3

Completion of installation and commissioning of thin oil station

6.2.4

Completion of installation and commissioning of industrial cooling water system

6.2.5

The FDF and its inner part shall be free from sundries.

6.2.6

The devices and valves have been tagged and named and are consistent with the system.

6.2.7

Each manhole door is closed in the system.

6.3

Necessary requirements for electrical engineering and I&C

6.3.1

After the calibration for the measuring points and measuring elements in the system, the installation and debugging are completed, providing with the application condition.

6.3.2

The commissioning of the thin oil station is completed and in good condition with normal parameter and correct CRT.

6.3.3

The single commissioning of the valve is completed and the on/off operation is normal with correct site location of limit switches and CRT display.

6.3.4

Completion of interlock protection alarm test for FDF system

6.3.5

The electrical test is qualified and in good condition after 2h no-load running with correct rotation direction.

6.4

Other necessary requirements

6.4.1

The joint inspection shall be organized by such parties as construction, Dongfang Electric, employer, production and commissioning; the problems found should be dealt completely

6.4.2

The preparation for production commissioning is completed. The operators should be



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arranged completely and qualified via the training and examination. The operation scheme and system drawing have been reviewed and approved. The operating tools and the operation log are prepared properly. 6.4.3

Necessary inspection and maintenance tools and materials should be provided.

6.4.4

Sound commissioning command and organization system and explicit division of labor.

6.4.5

Commissioning data, tools, apparatus, instrument and record list are prepared completely.

6.4.6

Person in charge of the commissioning of the instrument control, electricity as well as machine maintenance of the installation unit are present.

6.4.7

Completion of measure communication work

7.


7.1

7.2

7.3



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◆


◆


◆


◆


◆




◆


◆


◆


◆



7.4





7.5

7.6


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◆


◆


◆


◆




◆


◆


◆




◆


◆


8.


8.1


8.1.1

Check and accept the on/off damper of motorized and pneumatic switches, record the following data: Whether the KKS code, designation and the indication for the site valve are correct; whether the remote operation direction and feedback are correct, on/off time for the damper, test date, signature of person in charger of the test; refer to Appendix 4 for other contents

8.1.2

Check the motorized or pneumatic regulating valves and enter the following data on the records: Whether the KKS code, designation, local position indications, feedback indications corresponding to upward command of 0%, 50%, 75%, and 100%, and downward command of 100%, 75%, 50% and 0% respectively and local position indication are confirmed to be correct; the test date and the signature by person in charge of test refer to Appendix 3.

8.2

Interlock protection and alarm inspection (note: the test item on interlock protection is based on the discuss result on logic.)

8.2.1

The power supply of the FDF shall be placed in the test location to inspect the items below: (1) Start the FDF through computer and feedback on computer is correct; (2) Stop the FDF through computer and feedback on computer is correct; (3) Reliable emergency buttons

8.2.2

Interlock protection test of the FDF (note: the test item on interlock protection is based on the



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Page 7 of 24

discuss result on logic.) 8.2.2.1

Inspection on permissive conditions for FDF A (B) starting

No.

Test item

Inspection on startup permissive conditions for FDF A (1)

Tripping condition for FDF A does not exist.

(2)

FDF A stops

(3)

Moving blade of FDF A is closed

(4)

Damper at outlet of the FDF A is closed

(5)

Oil station of the FDF A is in normal

(6)

Any induced draft fan is running(induced draft fan A runs with inlet/outlet valves opened, or induced draft fan B is running with inlet/outlet valves opened, and the interconnection valve at inlet of deduster has been opened.)

(7)

FDF B is running with opened outlet damper, or FDF B stops with the moving blade not closed to the right position

(8)

The secondary air outlet damper of the air preheater A is opened, or the outlet interconnection valve of FDF has been opened with opened secondary air outlet damper of the air preheater B

(9)

The bearing temperature of the FDF A is not high(<95℃)

(10)

The motor coil temperature of the FDF A is not high(<125℃)

(11)

The motor bearing temperature of the FDF A is not high(<85℃)

(12)

No FSSS natural ventilation request

Inspection on startup permissive conditions for FDF B (13)

Tripping condition for FDF B does not exist.

(14)

FDF B stops

(15)

Moving blade of FDF B is closed

(16)

Outlet damper of the FDF A is closed

(17)

Oil station of the FDF A is in normal

(18)

Any induced draft fan is running(induced draft fan A runs with inlet/outlet valves opened , or induced draft fan B is running with opened in/out valves and outlet damper of the deduster)

(19)

FDF A is running with opened outlet damper, or FDF

Fixed value

Results

Remarks



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A stops with the blade not closed to the right position

(20)

The secondary air outlet damper of the air preheater B is opened, or the outlet interconnection valve for the FDF is opened with opened secondary air outlet damper of the air preheater A

(21)

The bearing temperature of the FDF B is not high(<95℃)

(22)

The motor coil temperature of the FDF B is not high(<125℃)

(23)

The motor bearing temperature of the FDF B is not high(<85℃)

(24)

No FSSS natural ventilation request

8.3.2.2

Interlock test for the outlet damper and moving blade of FDF

No.

Test item

(1)

When FDF starts, the outlet damper shall be opened by means of interlock in 30s later. If FDF on the other side is not running, close the outlet damper and blade of the suspended FDF by means of interlock

(2)

When FDF stops, and FDF on the other side is still running, close the outlet damper by means of interlock and blade of the suspended FDF

(3)

If the two FDFs stop, open the blade and outlet damper by means of interlock after 60s in delay.(FSSS natural ventilation)

(4)

When FDF is running, closure of the outlet damper is forbidden.

8.3.2.2

Results

Remarks

Interlock test for the outlet interconnection damper of the FDF

No.

Test item

(1)

Interlock starting conditions:(2) When FDF A and B stop, open the outlet interconnection damper by means of interlock after 80S in delay; or either FDF is running with 2 air preheaters running

(2)

Fixed value

Conditions for interlock closing (2) Air preheater A stops and FDF B is running, or air preheater B stops and FDF A is running, or FDF A stops for 65s in delay and FDF B is running, and outlet damper of the FDF A is opened with the moving blade not closed to the right place, or FDF B stops for 65s and FDF A is running, and outlet damper of the FDF B

Fixed value

Results

Remarks


is opened with place

8.3.2.2


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Page 9 of 24

moving blade not closed to the right

Interlock test on oil station of FDF

No.

Test item

Oil station of FDF A (1)

Startup permissive condition: the oil level in the oil tank of oil station is not low

(2)

Shutdown permissive condition: 5 minutes after FDF A stopped

(3)

When interlock is put into service, FDF A and #1 oil pump are running, the oil pressure in oil station of the FDF A is low, open the #2 oil pump by means of interlock

(4)

When interlock is put into service, FDF A is running with #1 oil pump tripped, open the #2 oil pump by means of interlock and #2 oil pump in oil station of the FDF A is not running

(5)

When interlock is put into service, FDF A and #2 oil pump are running, open the #1 oil pump by means of interlock and the oil pressure in oil station of the FDF A is low

(6)

When interlock is put into service, FDF A is running with #2 oil pump tripped, open the #1 oil pump by means of interlock and #1 oil pump in oil station of the FDF A is not running

Heater in the FDF A oil station (1)

Heater startup permissive condition: any oil pump of the FDF A is running and the oil level is not low

(2)

Interlock starting condition of heater: when interlock is put into service, any oil pump of the FDF A is running and the oil temperature is low

(3)

Conditions for interlock suspension: when interlock is put into service, oil temperature in the oil tank of FDF A oil station is high, or the oil level is low

FDF B oil station (1)

Startup permissive condition: the oil level in the station is not low

(2)

Shutdown permissive condition: 5 minutes after FDF A stops

(3)

When interlock is put into service and FDF B and #1 oil pump are running, open the #2 oil pump by means of interlock and the oil pressure in oil station of the FDF B is low

Fixed value

Results

Remarks



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(4)

When interlock is put into service and FDF B is running with #1 oil pump tripped, open the #2 oil pump by means of interlock and #2 oil pump in oil station of the FDF B is not running

(5)

When interlock is put into service and FDF B and #2 oil pump are running, open the #1 oil pump by means of interlock and the oil pressure in oil station of the FDF B is low

(6)

When interlock is put into service and FDF B is running with #2 oil pump tripped, open the #1 oil pump by means of interlock and #1 oil pump in oil station of the FDF B is not running

Heater in the FDF B oil station (1)

Heater startup permissive condition: any oil pump of the FDF B is running and the oil level is not low

(2)

Interlock starting condition: when interlock is put into service, any oil pump of the FDF B is running and the oil temperature is low

(3)

Conditions for interlock suspension: when interlock is put into service, oil temperature in the oil tank of FDF B oil station is high, or oil level is low

8.3.2.3

Inspection on the alarm condition of FDF

No.

Test item

(1)

When bearing temperature of FDF is high, give an alarm

(2)

When motor bearing temperature of FDF is high, give an alarm

(3)

When motor coil temperature of FDF is high, give an alarm

(4)

When bearing vibration of FDF is serious, alarm

(5)

When motor bearing vibration of FDF is serious, give an alarm

(6)

When the oil level in the oil tank of the oil station is low, give an alarm

(7)

When the outlet oil temperature in the oil station of FDF is high, give an alarm

(8)

When the difference pressure of the stalling probe is high, give an alarm

(9)

When the outlet oil level is low in the oil station, give an alarm

(10)

When pressure in the oil station is high after cooling, give an alarm

Fixed value

Results

Remarks


8.3.2.4


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Inspection on the protection interlock tripping condition of FDF The FDF (A/B) will interlock trip when any of the following conditions appears

No.

Test item

Tripping condition for FDF A (1)

The outlet damper of FDF A is closed when it operates for 60S

(2)

FDF A is running, while the induced draft fan A stops

(3)

FDF A is running and the air preheater A stops

(4)

FSSS furnace pressure is high

(5)


(6)

Heavy vibration of drive-end bearing of FDF A in direction X

(7)

Big vibration of drive-end bearing of FDF A in direction Y

(8)

Heavy vibration of non driven-end bearing of FDF A in direction X

(9)

Heavy vibration of non driven-end bearing of FDF A in direction Y

(10)

Moving blade is greater than 10%, and stalling of FDF A is delayed for 10S

(11)

Abnormal oil supply of FDF A oil station

(12)

The bearing temperature of FDF A is high high for the first time

(13)

The motor bearing temperature of FDF A is high high for the first time

Tripping condition for FDF B (1)

The outlet damper of the FDF B is closed when it operates for 60S

(2)

FDF B is running, while the induced draft fan B stops

(3)

FDF B is running and the air preheater B stops

(4)

FSSS furnace pressure is high high

(5)


(6)

Heavy vibration of drive-end bearing of FDF B in direction X

(7)

Heavy vibration of drive-end bearing of FDF B in direction Y

(8)

Heavy vibration of non driven-end bearing of FDF B in direction X

Fixed value

Results

Remarks



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Page 12 of 24

(9)

Heavy vibration of non driven-end bearing of FDF B in direction Y

(10)

Moving blade is greater than 10%, and stalling of FDF A is delayed for 10S

(11)

Abnormal oil supply of FDF B oil station

(12)

The bearing temperature of FDF B is high high for the first time

(13)

The motor bearing temperature of FDF B is high high for the first time

8.3.2.5

Starting procedure of the sub-system of FDF A/B

No.

Test item

Fixed value

Results

Remarks

Starting procedure of FDF A (1)

Step 1: start the oil station

(2)

Step 2: close the outlet damper of FDF

(3)

Step 3: give commands to SCS, and close the moving blade

(4)

Step 4: start the FDF motor

(5)

Step 5: delay the time to open the outlet damper of the FDF

Starting procedure of FDF B (6)

Step 1: start the oil station

(7)

Step 2: close the outlet damper of FDF

(8)

Step 3: give order to SCS, and close the moving blade

(9)

Step 4: start the FDF motor

(10)

Step 5: delay the time to open the outlet damper of the FDF

8.4

Application and stop of FDF and its system

8.4.1


8.4.1.1

Ensure that the interlock test on FDF and its system is qualified.

8.4.1.2

Ensure that the flexibility of the baffle at outlet of FDF, rotor blade, and switches and the site openness is consistent with what shown on the CRT

8.4.1.3

The insulation of the related equipment for FDF and its system is qualified, providing with power supply.

8.4.1.4

All kinds of instruments and meters in the air supply system are put into operation.

8.4.1.5

Normal commissioning of the oil pump in the oil station of FDF



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Page 13 of 24

8.4.1.6

Normal cooling water system

8.4.1.7

Commissioning of one FDF

8.4.2

Start the FDF

8.4.2.1

Close the damper at outlet of the FDF

8.4.2.2

Start the hydraulic regulating oil station and require the feedback signal for the oil pump motor;

8.4.2.3

Close the moving blade of FDF;

8.4.2.4

Start the FDF and open the damper at the outlet

8.4.2.5

Adjust the blade to the angle required;

8.4.3

Stop the FDF

8.4.3.1

Close the moving blade of the FDF

8.4.3.2

Stop the FDF

8.4.3.3

Close the damper at outlet of FDF

8.4.3.4

Stop the oil pump in the oil station in delay;

8.5

Operation of system during integral start-up Operating reliability is tested according to the non-loading stage, loading stage, full loading stage and 30d reliable commissioning stage.

8.5.1

Dynamic regulation of system

8.5.1.1

The pressure of the oil system and the temperature adjustment

8.5.1.2

Adjustment of the air output;

8.5.1.3

Adjustment of secondary air pressure

8.5.2

Complete trial operation record Refers to Appendix 2 for the main parameters during starting commissioning

9.

Safety Measures

9.1


9.1.1

People of all parties taking part in the commissioning shall be aware and follow the safety rules in site and properly dressed and wear acceptable safety protection PPE.

9.1.2

In case that any accident damages the equipment or hurts person happened or possibly happen during commissioning, suspend commissioning immediately and put the equipment to the lowest energy state. Then investigate the cause and take corrective measures.

9.1.3


9.1.4


9.2



9.3


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Page 14 of 24

Injuries might be caused by rotating equipment during commissioning or test. Therefore, special care must be taken during work and do not touch the rotating components with tools or your hand。 Equipment Risk and Preventative Measures

9.3.1

Person in related unit must strictly observe at the site during the first commissioning of the FDF and its system and contact with the center control room through reliable communication methods.

9.3.2

The starting time and electric current should be strictly observed during the commissioning of FDF. The swing should be stopped when starting time is too long or the current is abnormal.

9.3.3

Pay attention to the direction of the rotation when the FDF starts. Stop it when it turns to the opposite direction.

9.3.4

Observe the changes of such parameters as the oil pressure, oil temperature, bearing temperature, oscillation and current, preventing the occurrence of severe accident.

10.

Appendix



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Items

Requirements

Result

Environmental condition (1)

Sites, roads and surroundings

Flat, clear, clean

□Yes □No

(2)

Platform, staircase, rail, guard board, and scaffold for construction

Complete Demolished

□Yes □No

(3)

Illumination

Sufficient

□Yes □No

(4)

Communication facilities

Reliable

□Yes □No

(5)

Fire apparatus

Adequate and convenient

□Yes □No

2.

Maintenance conditions (1)

Installation and heat insulation

All fulfilled

□Yes □No

(2)

Single commissioning of FDF s

Qualified

□Yes □No

(3)

Thin oil station

Qualified debugging

□Yes □No

(4)


Debugging is completed and can be put into application

□Yes □No

(5)

Inner sundries

Completion of cleaning

□Yes □No

(6)

Facilities and valves

listed and named correctly

□Yes □No

(7)

Manhole door

Closed fully

□Yes □No

Conditions for electrical and I&C

3. (1)

Measuring point and measuring meter

Qualified calibration and correct indication

□Yes □No

(2)

Thin oil station

The operation is in order with correct indication

□Yes □No

(3)

Single Valve

The commissioning is completed with normal operation and correct indication

□Yes □No

(4)


Test eligible

□Yes □No

(5)


Qualified test and good condition for 2h no-load running with correct rotation direction

□Yes □No

Defects handling are completed.

□Yes □No

4.

Other conditions (1)

System inspection work

Verifie d by

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(2)


The operators and the operation instrument and running log are complete.

□Yes □No

(3)


Complete

□Yes □No

(4)

Command and organizing system

Sound and clear division of work

□Yes □No

(5)

Commissioning data, tools, instruments, meters and record sheets

Well-prepared

□Yes □No

(6)

Maintainer

Sufficient quantity and qualified training

□Yes □No

(7)

Disclosure work of measures

Fulfilled

□Yes □No


Contractor:

Date:

Date:


Dongfang Electric:

Date:

Date:



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Appendix 2 Trial Operation Parameters of FDF and Its System Trial Operation Parameters of FDF and Its System No.

Item

Unit

1

Position indication of moving blade of FDF A

%

2

Motor current of FDF A

A

3

Outlet pressure of FDF A

KPa

4

Difference pressure (DP) of FDF A

KPa

5

Bearing vibration of FDF A

mm/s

6

Secondary air temperature at the outlet of APH A

℃

7

Secondary air temperature at the inlet of APH A

℃

8

Bearing temperature of the FDF A

℃

9

Secondary air pressure at the outlet of APH A

KPa

10

Secondary air difference pressure between outlet and inlet of APH A

KPa

11

Inlet air temperature of FDF A

℃

12

Outlet air temperature of FDF A

℃

13

Motor bearing temperature of FDF A

℃

14

Motor winding temperature of FDF A

℃

15

Position indication of moving blade of FDF B

%

16

B FD fan current Motor current of FDF B

A

17

Outlet pressure of FDF B

KPa

18

Difference pressure (DP) of FDF B

KPa

19

Bearing vibration of FDF B

mm/s

20

Secondary air temperature at the outlet of APH B

℃

21

Secondary air temperature at the inlet of APH B

℃

22

Bearing temperature of the FDF B

℃

23

Secondary air pressure at the outlet of APH B

KPa

24

Secondary air difference pressure between outlet and inlet of APH B

KPa

Data

Remarks



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Page 18 of 24

25

Inlet air temperature of FDF B

℃

26

Inlet air temperature of FDF B

℃

27

Motor bearing temperature of FDF B

℃

28

Motor winding temperature of FDF B

℃


Contractor:

Date:

Date:


Dongfang Electric:

Date:

Date:



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Appendix 3 Control Damper Commissioning Record of FDF and Its System

KKS code

Damper

X0HLB10AA101

Moving blade of FDF A

X0HLB20AA101

Moving blade of FDF B

X0HLA11AA001 X0HLA21AA001 X0HLA31AA001 X0HLA41AA001 X0HLA11AA002 X0HLA21AA002 X0HLA31AA002 X0HLA41AA002 X0HLA11AA003 X0HLA21AA003

CORNER #1 LAYER AA SA DAMPER CORNER #2 LAYER AA SA DAMPER CORNER #3 LAYER AA SA DAMPER CORNER #4 LAYER AA SA DAMPER CORNER #1 LAYER A SA DAMPER CORNER #2 LAYER A SA DAMPER CORNER #3 LAYER A SA DAMPER CORNER #4 LAYER A SA DAMPER CORNER #1 LAYER AB SA DAMPER CORNER #2 LAYER AB SA DAMPER

Control Damper Commissioning Record of FDF and Its System Feedback corresponding to ascending and descending instruction values 0%

25%

50%

75%

100%

75%

50%

25%

0%

Date

Result

Signa ture

Remar ks


KKS code X0HLA31AA003 X0HLA41AA003 X0HLA11AA004 X0HLA21AA004 X0HLA31AA004 X0HLA41AA004 X0HLA11AA005 X0HLA21AA005 X0HLA31AA005 X0HLA41AA005 X0HLA11AA006 X0HLA21AA006 X0HLA31AA006 X0HLA41AA007

Damper CORNER #3 LAYER AB SA DAMPER CORNER #4 LAYER AB SA DAMPER CORNER #1 LAYER B SA DAMPER CORNER #2 LAYER B SA DAMPER CORNER #3 LAYER B SA DAMPER CORNER #4 LAYER B SA DAMPER CORNER #1 LAYER BC SA DAMPER CORNER #2 LAYER BC SA DAMPER CORNER #3 LAYER BC SA DAMPER CORNER #4 LAYER BC SA DAMPER CORNER #1 LAYER C SA DAMPER CORNER #2 LAYER C SA DAMPER CORNER #1 LAYER C SA DAMPER CORNER #4 LAYER C SA DAMPER


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Feedback corresponding to ascending and descending instruction values 0%

25%

50%

75%

100%

75%

50%

25%

0%

Date

Result

Signa ture

Remar ks


KKS code X0HLA11AA007 X0HLA21AA007 X0HLA31AA007 X0HLA41AA007 X0HLA11AA008 X0HLA21AA008 X0HLA31AA008 X0HLA41AA008 X0HLA11AA009 X0HLA21AA009 X0HLA31AA009 X0HLA41AA009 X0HLA11AA010

Damper CORNER #1 LAYER CC SA DAMPER CORNER #2 LAYER CC SA DAMPER CORNER #3 LAYER CC SA DAMPER CORNER #4 LAYER CC SA DAMPER CORNER #1 LAYER DD SA DAMPER CORNER #2 LAYER DD SA DAMPER CORNER #3 LAYER DD SA DAMPER CORNER #4 LAYER DD SA DAMPER CORNER #1 LAYER D SA DAMPER CORNER #2 LAYER D SA DAMPER CORNER #2 LAYER D3 SA DAMPER CORNER #4 LAYER D SA DAMPER CORNER #1 LAYER DE SA DAMPER


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25%

50%

75%

100%

75%

50%

25%

0%

Date

Result

Signa ture

Remar ks


KKS code X0HLA21AA010 X0HLA31AA010 X0HLA41AA010 X0HLA11AA011 X0HLA21AA011 X0HLA31AA011 X0HLA41AA011 X0HLA11AA012 X0HLA21AA012 X0HLA31AA012 X0HLA41AA012 X0HLA11AA013 X0HLA21AA013

Damper CORNER #2 LAYER DE SA DAMPER CORNER #3 LAYER DE SA DAMPER CORNER #4 LAYER DE SA DAMPER CORNER #1 LAYER E SA DAMPER CORNER #2 LAYER E SA DAMPER CORNER #1 LAYER E SA DAMPER CORNER #4 LAYER E SA DAMPER CORNER #1 LAYER EF SA DAMPER CORNER #2 LAYER EF SA DAMPER CORNER #3 LAYER EF SA DAMPER CORNER #4 LAYER EF SA DAMPER CORNER #1 LAYER OFF SA DAMPER CORNER #2 LAYER OFA SA DAMPER


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25%

50%

75%

100%

75%

50%

25%

0%

Date

Result

Signa ture

Remar ks


KKS code X0HLA31AA013 X0HLA41AA013 1HLA16 AA 700 1HLA26 AA 700

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Feedback corresponding to ascending and descending instruction values

Damper

0%

25%

50%

75%

100%

75%

50%

CORNER #3 LAYER OFF SA DAMPER CORNER #4 LAYER OFF SA DAMPER S-A HSA RECYCLE CONTROL DAMPER S-B HSA RECYCLE CONTROL DAMPER


Contractor:


Date:

Date:


Dongfang Electric:

Date:

Date:

25%

0%

Date

Result

Signa ture

Remar ks



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Appendix 4 FDF Dampers Commissioning Record FDF Dampers Commissioning Record Local position indication

KKS code

Damper

X0HLA10AA001 X0HLA20AA001

FDF A OUTLET MOTOR DAMPER FDF B OUTLET MOTOR DAMPER FDF OUTLET CONNECT MOTOR DAMPER APH A SA OUTLET MOTOR DAMPER 1 APH A SA OUTLET MOTOR DAMPER 2 APH B SA INLET MOTOR DAMPER 1 APH B SA INLET MOTOR DAMPER 2

X0HLA30AA001 X0HLA10AA002a X0HLA10AA002b X0HLA20AA002a X0HLA20AA002b


Date:

Date:

Remote Direction


Feedback

Date: Date:

On/Off Time On Off (Open) (Close)

Date

Result

Signa ture

Rema rks


Procedure of Pulverizing System

REV A


Page 1 of 35



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-M-01-EBC-001 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI

CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY


SiChuan Electric Power Commissioning & Test Institute Check Design Scale

N/A


DETAIL DESIGN STAGE

Procedure of Pulverizing System DWG No.


REV

A



REV A


Page 2 of 35


PURPOSE .................................................................................................................................... 3

2.

SCOPE ......................................................................................................................................... 3

3.


4.

BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT ....................................................... 3

5.


6.


7.

MEASURES FOR COMMISSIONING ORGANIZATION ....................................................... 6

8.

COMMISSIONING PROCEDURE ............................................................................................ 8

9.

SAFETY MEASURES .............................................................................................................. 23

10.

9.1


9.2


9.3


9.4

Safety Precautions ............................................................................................ 24 APPENDIX................................................................................................................................ 25

10.1


10.2

Appendix Trial Operation Parameters of Pulverized Coal System .................. 28

10.3

Appendix 3 Checklist of Dampers in Pulverized Coal System........................ 30

10.4

Appendix 4 Checklist of Control Dampers of Pulverized Coal System .......... 35



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Page 3 of 35

1.

Purpose

1.1

The Procedure has been prepared to guide and standardize system & equipment commissioning and ensure that the systems and equipments can be put into operation safely and normally.

1.2

To check electric and I&C protection, interlock and signal devices and confirm their proper operation.

1.3


2.

Scope This Procedure applies to commissioning of pulverizing system. The scope of commissioning contains confirmation of damper baffle, interlock protection test, system being put into operation, dynamic adjustment, etc.

3.

Preparation Basis

3.1

Operation and Maintenance Manual of HP963 Medium Speed Bowl Mill for Coal

3.2

Instruction Manual of Coal Feeder

3.3

Boiler pulverizing system diagram

4.


4.1

Brief Introduction of the System The pulverizing system of boiler comprises 5 HP963 medium speed bowl mills for coal, four in operation while one in standby mode. Each pulverizing system consists of coal feed pipe, pulverized coal pipe, pulverized coal separator, roller and its loader, bowl, gearbox, motor and etc. The coal mill motor drives rollers rotating via gear transmission. Three separated, spring-loaded rollers that can rotate freely around its own axis are evenly spaced above the mill bowl, and certain clearance is kept between rollers and liner of bowl in such a way that a pulverizing area is formed. Raw coal from a coal yard is conveyed into a feeder through coal bin and chute. Coal feeder, featured by automatically controlled revolution speed conveys the coal from the outlet of chute to outlet of feeder with the aid of belt conveyer. The raw coal drops on bowl of coal mill through feed pipe, then is sent into pulverizing area by centrifugal force, where it is rolled, ground and pulverized, and overflows from periphery of bowl. Primary air from primary fan, heated by preheater, comes tangentially into the coal mill through air inlet at the bottom of mill, and is mixed with the pulverized coal overflowed from bowl to form air- pulverized coal mixture. Pulverized coal is dried and lifted by hot air. The heavy particulates return to bowl by hitting on liner of separator (so called primary separation) while light particulates come through adjustable deflector, where some particulates with relatively large size return to bowl by hitting on top casing of separator and by centrifugal force caused by deflecting (so called secondary separation) while fine air- pulverized coal mixture flows into inner cone. The vane of deflector generates cyclone in air- pulverized coal mixture to centrifugally separate it (so called tertiary separation) in such a way that pulverized coal without qualified size is sent back to bowl of coal mill for further milling. Qualified pulverized coal passes through Venturi tube, coal mill outlet and throttle adjusting funnel, then comes into furnace for combustion. The angle of deflector vanes of coal mill determines the velocity of cyclone and ultimate size



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of pulverized coal. The angle shall be confirmed by test and is generally not be regulated during operation. In addition, the impurities in raw coal that are difficult to mill, such as pebbles, gangues, iron slag drop to bottom of mill via nozzle due to gravity, then be discharged into slag hopper via slag removal flap by scraper that rotates together with bowl. 4.2

Technical specifications of system and equipment

4.2.1

Coal mill

4.2.2

Model of coal mill:

HP963

Manufacturer:

Shanghai Heavy Machinery Plant Co., Ltd.

Standard grinding output:

58.5t/h（when R90＝32％，Hardgrove index HGI＝64）

Nameplate rating:

32.6t/h

Max. air flow at coal mill inlet:

18.69kg/s

Abrasive wheel rotating speed:

26.4r/min

Motor of coal mill Model

Motor of coal mill

YMKQ500—6.6

Power

kW

450

Voltage

V

6600

Rated current

A

Rotation speed

r/min

990

Power consumption at 100﹪ output of coal mill

kWh/t

6-10

Insulation class 4.2.3

F

Gear reducer of coal mill

Gear reducer

Oil pump in lubrication oil station

Oil pump motor

Electric heater

Model

MLX60-C1

Speed of input shaft

r/min

977

Speed of output shaft

r/min

32．84

Model of oil pump

SNH21OR43U121W21 screw pump

Flow

L/min

175

Operating pressure

MPa

0.8

Working oil temperature

℃

30－60

Model of motor

Y132M-4/7.5

Rated power

kW

7.5

Voltage

V

380

Current

A

15.6

Rotary speed

r/min

1450

Rated power

kW

1.5


Filter

Cooler

4.2.4


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Voltage

V

380

Q'ty

Heaters / mill

5

Model No.

XYC001-000

Filter rating

Μm

Model No.

2LAFW-F10

Cooling area

m2

16

Oil side pressure

MPa

1.2

Water side pressure

MPa

0.8

Coal feeder and technical specifications

Description

Coal feeder

Item

Unit

Value

Type

Electronic weighing type

Model No.

Q'ty

set

5

Output

Length

m

5

Precision class Model No. Motor of coal feeder

5.

Item

Unit

Value

GM-BSC22 T/h

5～50

Belt conveyer speed

r/min

1.3～13

Rotation speed

r/min

1410

A

4.0

1 ND100LS4

Power

kW

2.2

Current

Voltage

V

380

Output speed of reduction box

r/min

13

Rotation speed

r/min

1380

A

1.15

r/min

1.5

Model No. Sweeping motor

25

SH71D4

Power

kW

0.37

Current

Voltage

V

380

Output speed of reduction box

Tools and Instrument for Commissioning Instruments and apparatus used in the commissioning of coal pulverizing system include: Vibrometer, tachometer, infrared thermometer, clip-on ammeter and sound intensity meter

6.

Prerequisite for Commissioning Prior to system commissioning, the commissioning personnel shall perform complete inspection upon the prerequisite for system commissioning according to Appendix 1 (Commissioning Condition Checklist) and enter the result of check on records accordingly.

6.1


6.1.1

Within the extent of system, the ground is leveled, passage clear, trench cover complete and surroundings clean and free of foreign items.

6.1.2

Within the extent of system, platforms, ladders, railings and guards are completed and scaffold for construction has been removed totally.



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6.1.3

There shall be adequate formal lighting on the site. Set up temporary lighting if necessary.

6.1.4

There are reliable communication devices available on the site.

6.1.5

There are adequate fire-fighting apparatuses on the site.

6.2


6.2.1

Installation and heat-insulation of equipments, piping and accessories in system are over.

6.2.2

Single equipment of coal mill and coal feeder have passed through trial run.

6.2.3

Installation and commissioning of thin oil station are finished.

6.2.4

Installation and commissioning of industrial cooling water system are finished.

6.2.5

Foreign matters in coal mill system have been cleared away.

6.2.6

Equipments and valves have been tagged, which conform with the system.

6.2.7

Manholes within the system are closed.

6.2.8

Gauging hole for calibrating air flow device and speed-measuring device for trimming primary air have been machined and mounted. Test platforms are secure and reliable.

6.3


6.3.1

Measurement points and measuring elements in the system have been calibrated, installed and commissioned, and are ready to operate.

6.3.2

Thin oil station has been commissioned and proven in good operating condition with normal parameters. Status indications displayed on CRT are correct.

6.3.3

Valves have been commissioned individually, and proven to open and close properly. Location of limit switch and status indications displayed on CRT are correct.

6.3.4

Interlock protection alarm of the system has been tested.

6.3.5

Motors have passed through electric test successfully, and are in good condition and rotate in correct direction in two running hours without load.

6.4

Other conditions that must be available

6.4.1

All troubles found in combined examination implemented by Dongfang Electric, the Owner and parties involving in construction, production and commission have been solved.

6.4.2

The system is ready for trial run and staffed completely. The operators have passed through training examination successfully. Running procedure and system drawings have been approved. Tools for operating are equipped with, and running log is prepared.

6.4.3

Prepare maintenance tools and materials necessary for commissioning.

6.4.4

Command group of trial run is well organized and its functions are clearly allocated.

6.4.5

Documents, tools, apparatuses, instruments and record sheet have been prepared completely for commissioning.

6.4.6

Persons involving in instrument control, electrical and mechanical commissioning are present.

6.4.7

Measures disclosure is finished.

7.

Measures for Commissioning Organization This procedure shall be executed under the organization of commissioning contractor. The construction contractors shall cooperate closely with each other according to their respective work responsibilities so as to guarantee safe and effective implementation of commissioning.



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The division of works is as follows: 7.1

7.2

7.3

Responsibilities of Commissioning Contractor













Be responsible for segregation of system and temporary tagging for relative systems and equipments.

Responsibilities of Equipment Manufacturers

7.4

7.5

7.6


Responsibilities of Plant Operator



Operate the system and equipment according to the operating procedures or orders given by commissioning personnel;

Make patrol inspection, check, start-up and stop, and normal maintenance of systems and equipments.

Be responsible for dealing with the accidents occurred in commissioning

Being responsible for formal labeling of related systems and equipments.

Responsibilities of Dongfang Electric





Responsibilities of the Owner



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8.


8.1


8.1.1

Carry out acceptance check to electrical or pneumatic air damper and record data as follows: KKS code, name; local position indication, remote direction and feedback; on/ off time of damper, test date, signature of commissioning contractor. Refer to Appendix 3 for other contents.

8.1.2

Check the motorized or pneumatic regulating valves and enter the following data on the records; KKS code, designation, local position indications and feedback indications corresponding to upward command of 0%, 50%, 75%, and 100% and downward command of 100%, 75%, 50% and 0% respectively, confirm if local position indication is correct, test date, signature by person in charge of test. Refer to Appendix 4 for other requirements.

8.2

Check Interlock Protection and Alarms (Note: Interlock protection test items are to be determined by result of logic discussion.)

8.2.1

Place power supply of coal mill or feeder at test position. （1） Check following items: 1) Start coal mill or feeder from computer, and check if the feedback is correct. 2) Stop coal mill or feeder from computer, and check if the feedback is correct. （2） Emergency button shall work reliably.

8.2.2

Interlock protection test of pulverizing system

8.2.2.1

Check general conditions required by coal ignition. All of following conditions shall be satisfied.

No.

Test item

（1） No MFT Primary air permitting (any one of primary air fan （2） working and air pressure normal ) （3） Pressure of cooling air in flame scanning normal （4） Boiler air volume>30% Secondary air temperatures at Side A and B (at hot air （5） side of air preheater)>150℃ Or 8 oil guns at least put into service （6） Steam drum water level normal （7） Furnace pressure normal

Fixed value

Results

Remarks



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8.2.2.2

Check conditions at which coal input is permitted at corresponding coal layer.

1)

Coal layer A is permitted to be put into service if any of following conditions is satisfied. No.

Test item （1） General conditions required by coal ignition satisfied. Coal mill D put into service, and rotation speed of （2） feeder D > 50%, and boiler load > 30% （3） Oil layer AB or BC put into service.

Fixed value

Results

Remarks

（4） Boiler load＞60%ECR

2)

Coal layer B is permitted to be put into service if any of following conditions is satisfied. No.

Test item （1） General conditions required coal ignition satisfied. Coal mill E put into service, and rotation speed of （2） feeder E > 50%, and boiler load > 30% Coal Mill C put into service, and rotation speed of （3） Feeder C > 50%, and boiler load > 30% （4） Oil layer AB or BC put into service.

Fixed value

Results

Remarks

（5） Boiler load＞60%ECR

3)

Coal layer C is permitted to be put into service if any of following conditions is satisfied. No.

Test item （1） General conditions required coal ignition satisfied. Coal mill B put into service, and rotation speed of （2） feeder B > 50%, and boiler load > 30% Coal mill D put into service, and rotation speed of （3） feeder D > 50%, and boiler load > 30% （4） Oil layer BC put into service

Fixed value

Results

Remarks

（5） Boiler load＞60%

4)

Coal layer D is permitted to be put into service if any of following conditions is satisfied. No.

Test item

Fixed value

Results

Remarks



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（1） General conditions required coal ignition satisfied. Coal mill A put into service, and rotation speed of （2） feeder A > 50%, and boiler load > 30% Coal mill C put into service, and rotation speed of （3） feeder C > 50%, and boiler load > 30% Coal mill D put into service, and rotation speed of （4） feeder D > 50%, and boiler load > 30% （5） Oil layer DE put into service （6） Boiler load＞60% 5)

Coal layer E is permitted to be put into service if any of following conditions is satisfied. No.

Test item （1） General conditions required coal ignition satisfied. Coal mill B put into service, and rotation speed of （2） feeder B > 50% （3） Oil layer DE put into service

Fixed value

Results

Remarks

（4） Boiler load＞60%

8.2.2.3 NO. （1）（2）

（3）

（4）（5）

Conditions required by starting mill set (following conditions shall be satisfied completely, and Mill A, B, C, D and E are same). Test item Coal of corresponding layer (milling layer) permitted to be put into service. No trip condition in coal mill Lubricating pump of mill running; lubricating condition of mill satisfied (pressure at lubricating pump outlet of mill not low; no Off signal at control power supply of lubrication station of mill; flow at lubricating pump outlet of mill not low; differential pressure between inlet and outlet of oil filter not high) Bearing temperature at shaft extension end and non-extension end normal (<90℃) Cold air damper opened; hot air damper opened.

（8）

Differential pressure between upper and lower side of mill bowl not high. Differential pressure between primary air and seal air of mill not low; seal air damper opened. No coal mill in start-up procedure

（9）

Outlet valve 3/4 opened of mill

（6）（7）

Coal air mixture temperature normal at mill outlet (65℃≤T≤85℃) （11） Primary air flow ≥50T／H Inlet valve opened and outlet valve closed at pebble （12） coal hopper of mill （10）

Fixed value

2kPa

Results

Remarks



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（13） Outlet damper of coal feeder closed.

8.2.2.4 No. （1）（2）（3）（4）

Conditions at which mill set trips (mill set will trip if any of following conditions is satisfied. Mill A, B, C, D and E are same.) Test item Primary air fans stop if any one of mills runs (time delayed for 2s) Any three outlet valves are closed during mill operating. (3 out 4 logic) Send out signal to actively stop mill from CRT.

（6）（7）

MFT actuated.

（8）

Local emergency button actuated.

（9）（10）

（11）

（12）（13）（14）（15）（16）（17）

8.2.2.5

Results

Remarks

Coal feeder trips, time delayed for 15 min. Flame-out: after coal feeder runs 2 min, any three coal burners at corresponding layer detect flame-out (3 out 4 logic), or any three scanners fail. Mill primary air flow ≤35t/h (time delayed for 5S)

（5）

Fixed value

Coal air mixture temperature at mill outlet ≥100℃ (time delayed for 2s) 2 out 3 logic. Differential pressure between mill seal air and primary air ≤1kPa (time delayed for 2s). Average of 2 differential pressures. Failure in lubricating oil system (low-low pressure at lubricating pump outlet, time delayed for 2s; or low level in oil tank of lubrication station, time delayed for 2s; or lubricating pumps stopping completely after running, time delayed for 2s.) High-high bearing temperature at shaft non-extension end of mill: 95℃ (time delayed for 2s). High-high bearing temperature at shaft extension end of mill: 95℃ (2 out of 6 logic) (time delayed for 2s). High-high temperature of motor winding of mill: 145℃(time delayed for 2s) High-high vibration in direction X and Y of mill: time delayed for 10s. Bearing temperature of epicyclic gearbox of mill >80℃ (2 out 4 logic), time delayed for 3s Input bearing temperature of gear box of mill >90℃ (1 out 2), time delayed for 3s Following valves are interlock-closed when mill trips (Mill A, B, C, D and E are same).

No.

Test item

（1） Fast swinging damper at cold air inlet of mill （2） Fast swinging damper of hot air of mill （3） Outlet vale of mill

Fixed value

Results

Remarks



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（4） Isolating valve at burner inlet (closed after delay) （5） Coal gate at feeder inlet （6） Coal gate at feeder outlet 8.2.2.6

Start-up procedure of coal mill: (Mill A, B, C, D and E are same.)

No.

Test item No.1 step: Start lubricating oil pump up. （1）（2） No.2 step: Open seal air damper of mill

Fixed value

Results

Remarks

Results

Remarks

（3） No.3 step: Open discharge valve of mill No.4 step: Open cold air shutoff valve and hot air （4） shutoff valve at mill inlet. No.5 step: Put cold/ hot air at mill inlet into auto mode. Initial temperature at mill outlet: 60-82℃; air flow at （5） mill inlet placed at minimum value: 50t/h. Warm mill up. Time delayed for 5 min. No.6 step: Start coal mill. （6）（7） No.7 step: Start seal air of coal feeder. （8） No.8 step: Open coal gate at feeder outlet No.9 step: Start coal feeder. Set the coal feed at （9） minimum rate, No.10 step: Open coal gate at feeder inlet. （ 10 ） 8.2.2.7

Shutdown procedure of coal mill (Mill A, B, C, D and E are same).

No.

Test item No.1 step: Set mill outlet temperature to shutdown （1） temperature. (50℃) （2） No.2 step: Close coal feeder inlet valve （3） No.3 step: Set rev. speed of feeder to minimum value.

Fixed value

No.4 step: Shut down coal feeder. Time delayed for 1 min. （5） No.5 step: Close coal feeder outlet valve No.6 step: Close mill hot air damper and open mill （6） cold air damper. （7） No.7 step: Shut down coal mill. （8） No.8 step: Close discharge valve of coal mill. （4）

8.2.2.8 No.

Conditions at which start-up of coal feeder is permitted (following conditions shall be satisfied completely. A, B, C, D and E are same). Test item

Fixed value

Results

Remarks



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（1） Coal input is permitted at corresponding mill. （2） Corresponding mill is running. There is no alarm condition such as no failure in scraper chain, no over temperature, no coal blockage. Seal /cooling air damper is opened and pressure is （4） normal. （5） There is no stop condition due to protection. （6） Coal feeder is specified to minimum feed (10%). （3）

（7） Feeder outlet valve is opened.

8.2.2.9 No.

Interlock trip condition of feeder (feeder will trip if any of following conditions is satisfied. A, B, C, D and E are same) Test item

Fixed value

Results

Remarks

（1） MFT （2） Coal mill trips or is put out of use. （3） Cooling air damper of feeder is closed. Coal discharging pipe of feeder blocks. Time delayed （4） for 5s. （5） Temperature is high inside feeder. Time delayed for 3s. （6） Feeder is running and outlet valve is closed.

8.2.2.10 No.

Following valves are interlock-closed when feeder trips (Feeder A, B, C, D and E are same). Test item

Fixed value

Results

Remarks

（1） Coal gate at feeder inlet is closed. （2） Coal gate at feeder outlet is closed. （3） Emergency coal unloading gate of feeder is closed.

8.2.2.11 No. (1) 1） (2) 1） 2） 3）

Interlock test of dampers of pulverizing system (Mill A, B, C, D and E are same.) Test item Pulverized coal damper at burner inlet Protection interlock-closing condition: Coal mill stopped (time delayed for 3s), interlock closing. Motorized valve of fire smotherring steam of mill Permissive opening conditions: Any one of seal air fans is running. Protection interlock opening conditions: Coal air mixture temperature at mill outlet higher than 100℃ (time delayed for 2s), or high CO concentration at mill outlet, or mill tripping. Protection interlock closing condition: Explosion proof steam valve is opened for 10 min and coal air mixture temperature at mill outlet lower than

Fixed value

Resu lts

Rem arks



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Value 1 (≤95℃) (2 out 3). (3)

Electric damper of mill seal air

1）

Permissive opening conditions: Primary fan running (time delayed for 5s)

2）

Permissive shutdown conditions：Coal mill stopped (time delayed for 5min) Interlock closing conditions: Any one of sealing fans not running, or mill stopped (time delayed for 30s), or low differential pressure between seal air and primary air of Mill A. Seal air damper at mill outlet

3） (4) 1）

Permissive opening conditions: Primary fan running (time delayed for 5s).

2）

Permissive shutdown conditions: Coal mill stopped (time delayed for 5min)

3）

Interlock closing conditions: Mill stopped (time delayed for 6s).

(5)

Fast swinging damper of cold air at mill inlet

1）

Permissive opening conditions: No MFT.

2）

Interlock closing conditions: MFT or mill tripping (pulse)

(6)

Fasting swinging damper of hot air at mill inlet

1）

Permissive opening conditions: No MFT

2）


(7)

Fast swinging damper at mill outlet

1）

Permissive opening conditions: No MFT

2）


(8) 1） 2） (9)

Seal air damper of feeder Permissive open conditions: Corresponding mill running. Permissive close conditions: Any sealing fan not running; or mill stopped (time delayed for 30s); or low differential pressure between seal air and primary air of Mill A. Coal gate at feeder inlet

1）

Permissive open conditions: Remote

2）

Permissive close conditions: Remote

3）

Interlock protection close conditions: Coal feeder stopped.

(10)

Coal gate at feeder outlet

1）


2）


3）

Interlock protection close conditions: Coal feeder stopped.

(11)

Emergency electric coal unloading gate of feeder

1）


2）


3）

Interlock protection close conditions: Coal mill stopped


8.2.2.12


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Lubricating oil pumps interlock test of coal mill (A, B, C, D and E are same.)

No.

Test item

Fixed value

Results

Remarks

Lubrication station of coal mill Permissive starting conditions of lubrication station: （1） Oil level in tank of station not low and oil temperature >15℃ Permissive shutdown conditions of lubrication station: （2） Mill stopped (time delayed for 5 min). When interlock is put into service and coal mill is running and No.1 oil pump is running, if oil pressure （3） of lubrication station of coal mill is low, No.2 oil pump will be interlock-started. When interlock is put into service and coal mill is running and No.1 oil pump which is running trips, if （4） No.2 oil pump in station is not running, it will be interlock-started. When interlock is put into service and coal mill is running and No.2 oil pump is running, if oil pressure （5） of lubrication station of coal mill is low, No.1 oil pump will be interlock-started. When interlock is put into service and coal mill is running and No.2 oil pump suffers running failure, if （6） No.1 oil pump in the station is not running, it will be interlock-started. Heater in lubrication station of coal mill Permissive starting conditions of heater in lubrication station: Any oil pump in lubrication station of mill （1） running and oil level in tank of station not low and oil temperature <35℃. Interlock starting conditions of heater: Any oil pump in lubrication station of coal mill and oil temperature in （2） tank of station is lower than 35℃ when interlock is put into service. Interlock shutdown conditions of heater: Oil temperature in tank of lubrication station of Mill A is （3） higher than 40℃, or oil level in tank is low when interlock is put into service. Heating coil in lubrication station of coal mill Interlock starting conditions: Outlet temperature of （1） lubricating oil pump of mill <45℃ Interlock shutdown conditions: Outlet temperature of （2） lubricating oil pump of mil l> 49℃ 8.3.

Trial Run of Coal Feeder and Calibration of Coal Feed Capacity

8.3.1

Trial run of coal feeder （1）

Confirm that installation of coal feeder is finished, and foreign matters inside it have been cleared away;

（2）

Confirm the power supply of the motor is in open position, and the insulation of the



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motor is qualified;

8.3.2

（3）

Confirm that the results of I&C protection test and valves test of coal feeder are passed;

（4）

Conform that coal feeder is permitted to start. Switch on the power supply and operating power supply of feeder;

（5）

During rotation, pay attention to any abnormal noise and record following datum: voltage and startup current;

（6）

During stop, check and make sure that the coal feeder rotates in the right direction, the belt doesn't slip out, no abnormal sound comes from rotation, and dynamic and static parts are free of friction;

（7）

After normal condition is proved by inspection, restart the coal feeder and keep trial operation for 8 hours while taking care to note down such information as running current, bearing vibration and bearing temperature.

Calibration of coal feed capacity After single coal feeder passes through trial run, cooperate the manufacturer to calibrate weighing of coal feeder with standard items. Be sure that the display of feed capacity of coal feeder is correct.

8.4

Trial Run of Coal Mill

8.4.1

Trial run of single coal mill motor

8.4.1.1

Confirm the installing of the motor is already finished;

8.4.1.2

Confirm the power supply of the motor is in open position, and the insulation of the motor is qualified；

8.4.1.3

Confirm that motor has disengaged from coupling of gear reducer of coal mill;

8.4.1.4

Operate motor rotor by hand, making sure dynamic and static parts are free of friction and bearings free of abnormal sound;

8.4.1.5

Confirm that result of protection test of mill motor is passed;

8.4.1.6

Turn on the motor and its controller to start up the motor；

8.4.1.7

Start the motor and use local emergency button to stop it. Keep an eye whether abnormal sound comes from rotation while noting down the following data: voltage and startup current;

8.4.1.8

During stop, check and make sure that the motor rotates in the right direction, no abnormal sound comes from rotation, and dynamic and static parts are free of friction；

8.4.1.9

After normal condition is proved by inspection, restart the motor and keep trial operation for 2 hours while taking care to note down such information as running current, bearing vibration and bearing temperature.

8.4.2

Trial run of coal mill:

8.4.2.1

Upon completion of trial operation of the motor, restore the coupling of motor and coal mill reducer and operate it by hand, to be normal；

8.4.2.2

Clearance between roller and bowl shall be adjusted larger temporarily. Clearance shall be adjusted to meet security requirement adequately.

8.4.2.3

Result of lubrication oil system test of coal mill is passed;

8.4.2.4

Start coal mill and shut down it after 5 seconds. Check:



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if the rotation direction of coal mill meets design requirement; if there is abnormal noise; if there is evident leakage and other abnormal condition in system. 8.4.2.5

If there is no abnormal condition, restart coal mill after 30 minutes. After mill is started, keep watch on current to prevent running with current higher than the rated. Write down parameters:

Starting time; Starting current and current fallback duration; Coal mill current; Voltage; Temperature of coal mill motor coil; Temperature of coal mill motor bearing; Vibration of coal mill. 8.4.2.6

Execute 8 hours of trial run on coal mill. Conduct acceptance check and signature if result of trial run is passed.

8.5

Check before initial startup of coal pulverizing system

8.5.1

Check of primary air system

8.5.1.1

Installation and maintenance work of the two primary air fans air completed. The air duct has no man, tools, sundries inside. All the manholes are closed.

8.5.1.2

Primary air system has passed through air pressure test successfully. Heat insulation of primary air system is in good condition.

8.5.1.3

All dampers, baffles in primary air system are closed. All executors are in good condition and powered. On-off actions are proved free and proper by checking and operating.

8.5.1.4

Oil level of fan bearing box is normal. Oil quality is good.

8.5.1.5

Hydraulic and lubrication oil stations of primary fan has been started. Oil level and pressure are normal. Oil quality is up to standard.

8.5.1.6

Cooling water system of fan bearing is normal and in operation.

8.5.1.7

Holding down bolts of fan and motor are tightly fixed.

8.5.2

Check of pulverizing plant

8.5.2.1

Internal check of coal mill (1)

Check that the return pulverized coal of separator has no sundries and jamming. Swing of the damper must be flexible and free.

(2)

Deflector baffle of mill separator has been adjusted preliminarily. The opening of deflector is set to scale mark 5. The optimum angle is to be determined by test of coal mill. Separator baffles are proved in same deflecting angle after internal check.

(3)

Roller springs is loaded, and all springs are compressed uniformly. Position adjustment of spring loading and clearance adjustment between roller sleeve and bowl liner satisfy the manufacturer’s requirement. Recorded data is complete.

(4)

Evenness of opening of separator deflector is identical with external indication.



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Opening of deflector is placed at scale mark 5 preliminarily.

8.5.2.2

8.5.2.3

8.5.2.4

8.5.2.5

8.5.2.6

(5)

The rollers have no oil leak phenomenon.

(6)

Installation, inspection and maintenance of coal mill are finished. There is no person, tools, sundries inside mill. Manholes of mill are closed.

(7)

Turning gear is completely tripped off.

Check of lubrication oil system of coal mill (1)

Installation and maintenance work of lubrication oil system of coal mill is completed. The system resumes to normal conditions.

(2)

Oil level of the oil tank of coal mill is normal. Oil quality is good.

(3)

Lubrication oil pump of the coal mill has been subject to 8 hour test run. Normal operation can be started.

(4)

Lubrication oil pump of coal mill can start normally, operate stably without abnormal noise.

(5)

Lubrication oil cooling water system of coal mill is normal without leak phenomenon. It can start normal operation.

(6)

Lubrication oil heating system of coal mill is normal. Automatic starting and stop function of heater is normal

Inspection of seal air system of coal mill (1)

Installation and maintenance work of seal fans of coal mill is completed. System has resumed normal condition.

(2)

Seal fan has been subject to 8 hour separate test run and has accepted by signing.

(3)

Seal air valves of coal mill are in good condition. Open/close direction is correct. Indication is accurate without error.

Inspection of steam fire smothering system of coal mill (1)

Installation and heat insulation work of steam fire smothering system of coal mill is completed.

(2)

Steam fire smothering system of coal mill has passed hydrostatic test and has no leak phenomenon.

(3)

Steam smothering drain system of coal mill is smooth.

(4)

Interlock relation of fire steam valve of coal mill is correct.

Inspection of pebble coal system of coal mill (1)

Pebble coal tank of coal mill has been cleaned without sundries inside.

(2)

Pebble coal primary and secondary discharge gate valves of coal mill can open and close normally. Logic relation is correct.

(3)

Confirm that pebble coal primary discharge gate is open and secondary discharge gate is closed。

Inspection of outlet pipe of coal mill (1)

The adjustable shrinkage hole of outlet primary air duct of coal mill has been adjusted and locked during primary air regulation test.

(2)

Open/close action of the quick close valve on the pulverized coal pipes is flexible.



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Open/close direction is correct.

8.5.2.7

(3)

The measuring points installed on the pulverized coal pipes have all been closed.

(4)

Heat insulation of pulverized coal pipes is in good condition and identification mark is clear。

Inspection of coal feeder system (1)

Installation and maintenance work of coal feeder is completed. The coal feeder is closed on both sides. The internal lighting of coal feeder is I good condition.

(2)

Combined static commissioning of coal feeder is completed. Automatic weighing system of coal feeder is calibrated correctly.

(3)

interlocking relation between coal feeder motor and purging motor is correct.

(4)

the coal feeder has passed 8 hour test run with no load.

(5)

Open/close action of baffle plate at the outlet and inlet of coal feeder is flexible and direction is correct. The interlock relation of inlet and outlet baffle plates is correct.

(6)

Seal air valves of coal feeder has flexible open/close action and clear identification mark.

8.5.2.8

Interlock protection test of primary air fan (seal air fan), coal mill and coal feeder is completed. Logic relation is correct.

8.5.2.9

Check and confirmation of other systems （1） Utilities

Instrument air compressor system and equipments operate properly, and are capable of supplying air with qualified pressure.

Cooling water system and equipments operate properly, and are capable of supplying water with required pressure and flow.

（2） Service power system is proved qualified and acceptance signature is issued after checking. The power system has been managed by producer and in the dispatching scope of shift chief-operator, who can cut off and switch on power according to trial run. （3） Coal handling system is in good condition, and its trial run is completed. It has been managed by producer and in the dispatching scope of shift chief-operator, and it is ready to convey coal at any time. Certain capacity of raw coal has been stored in raw coal bin. （4） Electric dust collector system is in good condition and relevant tests are completed. Acceptance signature is issued after checking. It has been managed by producer and in the dispatching scope of shift chief-operator. Heater of ash hopper and isolators of electric dust collector have been put into service in advance. （5） Ash- and clinker-removing system are in good condition and their trial runs are completed. Acceptance signature is issued after checking. 8.5.3

Pulverizing system being put into operation in hot state (first start of mill) （1） Pulverizing system has been checked before started. Result of interlock protection test is passed. Equipments in system are powered. （2） Confirm that fire prevention steam is in standby mode.



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（3） Start lubrication oil station of coal mill. Regulate oil pressure and temperature to normal value. Confirm that oil flow is normal. Start lubrication oil station of mill 2 hours in advance. According to function module of station, when oil temperature in reservoir is lower than 35℃, electric heater starts to work; when oil temperature in reservoir is higher than 40℃, electric heater is put out of use. (In winter, it is permitted that oil cooler is not put into service until half hour before mill is started.) （4） Confirm that following requirements of lubrication oil of coal mill are satisfied: pressure at lubrication oil pump outlet of mill is not low; there is no Off signal at control power supply of lubrication oil station; flow at lubrication oil pump is not low; differential pressure between inlet and outlet of lubrication oil pump is not high. （5） Confirm that hot air damper at mill inlet is closed; Cold blast valve of coal mill is closed; Seal air baffle plate of coal feeder is open; Raw coal hopper gate is open; Thin oil station of coal mill works properly; Thermal protection system is normal。（6） If there is coal deposit in coal mill, put blast- and fire-prevention steam into service for 6~10 min before primary air is put into use so as to prevent pulverized coal from blasting. （7） Start primary air fan. After primary air fan runs properly, open plug plate at inlet and outlet of mill to regulate primary air pressure to 7KPa--10Kpa (tentative). （8） Start seal air fan and build up seal air pressure. Open seal air dampers of coal mill. （9） Adjust and confirm differential pressure between mill seal air and primary air greater than 2kPa. Open seal air dampers in coal feeder and at inlet and outlet of coal mill. Put primary air pressure into auto mode. （10） Jog coal feeder locally to spread coal. Stop coal feeder after coal is spread on conveyor belt fully. （11） Build up primary air flow. Increase primary air flow to maximum value within 3 min, then purge system. Decrease primary air flow to minimum value 50t/h (70%ECR) after purging is over. （12） Control temperature rise of coal mill to 5℃/min or less. Control inlet temperature of coal mill to 150℃ and outlet temperature to 65～82℃. Put hot/ cold air damper baffles at mill inlet into auto mode. Warm coal mill up for 15 min. （13） Inform persons involving in installation and operation. Assign person specially to supervise equipments such as coal mill and primary air fan to make preparation for start of mill. If there is abnormal circumstance during starting procedure, report it to person in charge immediately, and press locally emergency button if necessary. （14） Inform persons involving in thermal control to make preparation to send out flame scanning signal of coal compulsively at once after coal mill is started. Obverse flame through flame TV or by local person. Report abnormal circumstance in time. Stop coal mill if necessary. （15） Desuperheating water is in standby mode. Put desuperheating water into service in time according to change of steam temperature. （16） Confirm that requirements of start of coal mill are satisfied and check running conditions locally. Start coal mill. Observe and record starting time and current. Confirm that requirements of corresponding coal layer putting into service are satisfied. Start coal feeder to feed coal at minimum capacity 8~10 t/h. If coal mill vibrates at low load, increase coal feed rate properly. In general, vibration will



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disappear when coal bed forms between bowl and rollers. （17） Increase coal feed gradually according to load. Regulate mill capacity according to boiler load. In certain range, there is a linear relation between mill capacity and primary air flow (Air-Coal Curve). Regulate Air-Coal Curve according to coal kind. （18） After coal mill runs stably, thermal control operator shall regulate fire scanners dynamically one by one according to notice from commissioning person or shift chief in commissioning. Put one scanner into service after regulate it, and observe it for some time until it works stably and reliably. （19） After coal mill runs stably, thermal control operator shall regulate and put mill into relative auto mode one by one according to notice from commissioning person or shift chief in commissioning. （20） Pulverized air flow and outlet temperature of mill shall be maintained in automatic control. Coal feed shall be put into auto control mode. If evident disturbance or unstable running occurs during the above-mentioned is put into automatics, operator shall switch them from auto mode to manual mode and regulate them to stable situation. （21） When the load of running mill(s) reaches 60--70%, the next mill shall be put into operation. （22） Sample and analyze pebble coal. If calorific value of pebble coal ＞12.5MJ/kg, analyze the cause and regulate the coal until its calorific value＜12.5MJ/kg. 8.7

Attentions in start-up of pulverizing system （1） In the first start-up of mill, send out flame scanning signal compulsively at once after mill is started, otherwise mill will trip because flame scanning signal can not be detected. However, flame scanning signal is compulsive, so flame shall be observed through flame TV or local person assigned specially. Mill shall be stopped immediately if pulverized coal is found unburned. Remedy the trouble and restart the mill after furnace temperature rises. （2） Brief vibration may occur in the first start-up of mill, which is normal. Increase coal feed rate to eliminate vibration, then adjust coal feed rate gradually to required rate. If mill vibrates violently or for longer time, shut down the mill immediately and remedy the trouble, then start it again. （3） Prepare desuperheating water before start coal mill. Adjust water level in steam drum lower slightly than the normal. Control the temperature and pressure of steam properly to lower limit. （4） When coal mill starts or stops, steam temperature, steam pressure and water level will fluctuate violently. Adjust feed water and desuperheating water in time. Contact steam turbine to increase or decrease load in good time. （5） After mill is put into operation, analyze fineness of pulverized coal in time and maintain it to the design size. Regulate burning and improve air distribution to ensure good combustion. （6） Keep watch on running parameters which shall be within normal range during mill operation. （7） Inform coal handling system to remove foreign matters in raw coal as much as possible in trial run to prevent foreign matters from entering mill to cause vibration.


8.8


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Dynamic monitor and maintenance of system When pulverizing system is put into operation, intensify inspection and monitor for rotating equipments; enhance supervision of running parameters. If any deviation is found, regulate it in time to ensure that system is in optimum running condition.

8.9

8.10

(1)

Supervision and maintenance of temperature at mill outlet;

(2)

Supervision and maintenance of air flow at mill inlet;

(3)

Current change of coal mill and feeder; maintenance of coal feed rate;

(4)

Change of lubrication oil temperature of coal mill; adjust cooling water rate if necessary;

(5)

Supervision of temperature of rolls and motor winding of coal mill;

(6)

Current change of primary air fans on both sides; deviation and adjustment of primary air pressure on both sides;

(7)

Supervision of bearing temperature of primary air fan; supervision of temperature of motor winding of primary air fan;

(8)

Supervision of seal air pressure and current of coal mill;

(9)

Observation, supervision and adjustment of combustion in furnace;

(10)

Supervision and regulation of steam temperature, steam pressure, water level and flue-gas temperatures of boiler;

(11)

Check pebble coal contained in raw coal every two hours in the initial period of mill running. Eliminate pebble coal in time to calculate its content in raw coal. If pebble coal content exceeds normal limit, find out the cause and remedy it.

Normal shutdown of pulverizing system (1)

The corresponding oil layer shall be capable of being put quickly into service before each pulverizing system stops.

(2)

Switch control of coal feeder from auto mode to manual mode. Decrease feeder speed gradually to minimum coal feed rate and decrease air flow to 70% rated air flow of mill. Strictly control normal temperature at mill outlet during the above-mentioned procedure.

(3)

After load of coal mill is reduced to the minimum, close correspondingly hot air damper of mill and open correspondingly cold air damper. Switch control of air flow and temperature to manual mode.

(4)

Shut down coal feeder and close the baffles at inlet and outlet of coal feeder when temperature at mill outlet drops to about 50℃. Keep coal mill running for another 5-10 min at least to eliminate coal deposit in bowl.

(5)

Shut down coal mill after coal deposit in mill is eliminated. Close the baffles at inlet and outlet of mill.

(6)

Maintain seal air pressure for 5-10 minutes after mill stops. Stop seal air.

(7)

Shut down lubrication oil station 15 min after mill stops.

(8)

Shut down primary air fan and close damper at outlet of primary air fan after all mills stop.

(9)

Shut down seal air fan.

Hot regulation of pulverizing system When pulverizing system is putting into operation, intensify supervision of equipments in



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system. If any deviation is found, regulate it in time to ensure that the system is in optimum running condition and combustion is stable in boiler. (1)

Regulation and test of fineness and uniformity of pulverized coal After pulverizing system is put into operation normally, measure the fineness and uniformity of pulverized coal in primary air. Regulate air flow and opening of deflector baffle in pulverizing system.

(2)

Regulation of air-coal ratio of pulverizing system Control temperature at mill outlet within normal range. Regulate opening of cold/ hot air dampers at mill inlet to change air flow of mill and to guarantee optimum air-coal ratio of pulverizing system under certain load.

(3)

Optimization of pulverizing system Regulate combustion mode and distribute combustion load reasonably according to boiler load requirement, steam temperature change of main heater and reheater to guarantee boiler parameters and economical efficiency in operation.

8.11

Running in trial start-up of entire system The entire system shall be subject to no-load running, on-load running, full-load running, 30-day reliability-demonstrating test to test reliability of system. (1) Dynamic regulation of system: During the system is putting into operation, especially in the regulation of fineness of pulverized coal and air flow, intensify the supervision of equipments to guarantee that the system is in optimum running condition. (2) Complete trial operation record: Refer to Appendix 2 for main parameters in trial start-up.

9.

Safety Measures

9.1


9.1.1


9.1.2


9.1.3


9.1.4

When the coal mill and its system start for the first time, the professional persons from all parties must be present to keep close watch on the operation, and can communicate with central control room through reliable communication devices.

9.2


Rotating equipment Injuries might be caused by rotating equipment during commissioning or test. Therefore, special care must be taken during work and do not touch the rotating components with tools or your hand。

Not wear helmet or wear helmet improperly. Injury or even death may be caused by impact of objects during regulating or test. Wear



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helmet properly and tie up chin strap when coming into production site. Check if there is risk of objects falling from height above and around job site.

Establishment of temporary test platform and scaffold is out of specification. It may cause injury to person. Do not use the platform or scaffold unless it is confirmed qualified after checking.

Not establish safety & protection facility or the facility is not complete. It may cause injury to person. Check the establishment of safety & protection facility before work.

High temperature flue-gas from observation hole and manhole may cause injury to person. Seal all manholes and close observation holes. Before observe flame locally, increase furnace pressure appropriately. When observe flame, stand at side of observation hole, and make preparation to evacuate at any time.

9.3


Abnormal operation of equipments If it is found that operating equipment emits abnormal sound or has other abnormal condition, and such problem may not be eliminated, stop such equipment and report to the control rooms immediately.

Over-temperature combustion within coal mill Operator shall take care to operate and maintain the coal mill, and control the temperature at mill outlet. Intensify patrol inspection and report abnormal circumstance as soon as it is found. Prepare appropriately temporary fire-fighting apparatuses, and fire-prevention steam of pulverizing system is in standby mode.

Unstable combustion, flame out or detonation Put fire prevention into service. Control size of pulverized coal grains reasonably. Put oil gun into service in time if combustion is unstable, and get ready to prevent accident.

Combustion of coal dust at tail and damage to equipment Analyze fineness of pulverized coal and maintain it within specified limits. Improve combustion regulation to guarantee combustion in good condition. Keep air preheater working to blow ash off. Maintain normal water level after furnace stops. Purge post-seal system with large air flow. Intensify supervision of flue-gas temperature at tail and remedy trouble if find it. Check irregularly the coal deposit in flue-gas duct in tail section of boiler. Purge boiler with large air flow before and after it restarts. Assign specially person to supervise the boiler and get the temporary fire-fighting apparatuses and fire water system here ready to use.

9.4

Safety Precautions

9.4.1

All operating personnel participating commissioning shall strictly follow Safety Regulations and related safety provisions at site, thus to ensure safe and reliable commissioning.

9.4.2

All operating personnel participating commissioning shall obey the arrangement and follow the direction. It is strictly forbidden to operate without authorization or against rules.

9.4.3

In case of abnormality during commissioning, adjust in time and report to commanding personnel immediately.

9.4.4

Power on and off of equipments shall be done according to relative regulations strictly.



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9.4.5

When the first pulverizing system is put into operation, the burner at lower layer shall be chosen as possible. Control temperature rise rate and pressure rise rate properly. During the initial period of mill putting into operation, observe combustion locally and regulate air distribution to facilitate combustion to reach optimum condition.

9.4.6

When regulating load, pay attention to increase air flow before increase coal feed rate if loading up and decrease coal feed rate before decrease air flow when unloading.

9.4.7

After pulverizing system is put into operation, intensify regular analysis and regulation of pulverized coal. Pay attention to combustion adjustment to guarantee operating condition stable and combustion complete in furnace and prevent furnace from explosion.

9.4.8

When coal burns in furnace, supervise measuring points on heat surface of boiler. Check regularly water-cooling wall and coking in the nozzle of burner, and put soot blower into operation regularly.

9.4.9

Enhance supervision of pulverizing system and regulate appropriately if necessary when increase or decrease boiler load, start and stop coal mill and coal feeder, coal outage or blockage occurs and quality of coal changes.

9.4.10

Personnel from all parties shall check the running conditions of equipments regularly and check if coal mill runs stably, there is abnormal noise and fiction, lubricant oil level, oil quality and temperature, bearing temperature, motor winding temperature and motor current are correct.

9.4.11

Supervise air pressure of each section of pulverizing system. Supervise and control temperature at mill outlet, current change of rotating machinery. If any abnormal circumstance is found, regulate to remedy it.

9.4.12

When start and shut down pulverizing system, keep close watch on mill air flow and regulate air flow in time to guarantee the air flow at inlet of each mill higher than 35 t/h and air temperature not less than 60℃ so as to avoid coal blockage in primary air tube.

9.4.13

If coal mill vibrates violently in start-up and operation, or running parameters (e.g. bearing temperature of coal mill) are out of standard significantly, commissioning person shall give order to stop equipment and suspend commissioning. Do not resume commissioning unless the cause is analyzed and found and trouble is remedied.

9.4.14

Reduce coal gangue content in fed coal to guarantee normal operation of coal mill. Coal crusher shall work properly to guarantee the size of coal grain ≤38mm.

9.4.15

After pulverizing system is put into operation, if the coal air mixture flow can not be ignited, stop the pulverizing system to check the cause. Restart it after trouble is remedied.

9.4.16

If there is much coal deposit in mill which will be out of use for long term, the coal deposit shall be removed to prevent it from spontaneous combustion.

9.4.17

Pulverizing system shall be started and shut down according to specified measures and procedures, and relevant preventative measures against the explosion shall be prepared.

10.

Appendix

10.1


Items

1.


(1)

Field, passage, surroundings

Requirements

Level, clear and clean

Result

□Yes □No

Verified by

Remarks



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(2)

Platform, ladder, railing, guard plate, scaffold

Completed Removed

□Yes □No

(3)

Lighting

Sufficient

□Yes □No

(4)

Communication devices

Reliable

□Yes □No

(5)

Fire apparatus

Adequate and easily accessible

□Yes □No

2.

Machinery conditions

(1)

Work of installation and heat insulation

All fulfilled

□Yes □No

(2)

Trial run of single equipment

Qualified

□Yes □No

(3)

Thin oil station

Commissioned and acceptable

□Yes □No

(4)


Commissioned and available

□Yes □No

(5)

Foreign matters inside

Removed

□Yes □No

(6)

Equipments and valves

Tagged and named correctly

□Yes □No

(7)

Manhole

Closed

□Yes □No

Manufactured and installed; platform secure and reliable

□Yes □No

(8)

Inspection hole

3.

Electric and I&C conditions

(1)

Measuring point and gauge

Qualified and indicating correctly

□Yes □No

(2)

Thin oil station

Running in good condition and indicating correctly

□Yes □No

(3)

Single piece of valve

Commissioned; working properly; correct status-indicating

□Yes □No

(4)


Test eligible

□Yes □No

(5)


Test eligible; in good condition and after 2 running hours without load; correct rotation direction

□Yes □No

4.

Others

(1)

Check of system

Checked and trouble remedied

□Yes □No

(2)


Operator completed; tools for running prepared; running log prepared.

□Yes □No

(3)


Complete

□Yes □No

(4)

Commanding group

Well organized and function allocated clearly

□Yes □No



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(5)

Documents, tools, instruments, gauges and sheets required by commissioning

In readiness

□Yes □No

(6)

Personnel for inspection and maintenance

Adequately staffed and well-trained

□Yes □No

(7)

Measures disclosure

Fulfilled

□Yes □No

Commissioning Company: Contractor：

Date:

Date:

Operation Contractor：

Dongfang Electric:

Date: Date:


10.2


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Appendix Trial Operation Parameters of Pulverized Coal System Trial Operation Parameters of Pulverized Coal System

No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45.

Item Primary air flow of mill A Inlet air pressure of mill A Outlet air pressure of mill A Differential pressure of mill A grinding roller Differential pressure of mill A Differential pressure of mill A grinding table Motor current of mill A Motor bearing temperature of mill A Motor winding temperature of mill A Inlet primary air pressure of mill A Feed coal output of coal feeder A Inlet temperature of mill A Outlet temperature of mill A Primary air flow of mill B Inlet air pressure of mill B Outlet air pressure of mill B Differential pressure of mill B grinding roller Differential pressure of mill B Differential pressure of mill B grinding table Motor current of mill B Motor bearing temperature of mill B Motor stator winding temperature of mill B Inlet primary air pressure of mill B Feed coal output of coal feeder B Inlet temperature of mill B Outlet temperature of mill B Primary air flow of mill C Inlet air pressure of mill C Outlet air pressure of mill C Differential pressure of mill C grinding roller Differential pressure of mill C Differential pressure of mill C grinding table Motor current of mill C Motor bearing temperature of mill C Motor stator winding temperature of mill C Inlet primary air pressure of mill C Feed coal output of coal feeder C Inlet temperature of mill C Outlet temperature of mill C Primary air flow of mill D Inlet air pressure of mill D Outlet air pressure of mill D Differential pressure of mill D grinding roller Differential pressure of mill D Differential pressure of mill D grinding table

Unit

Data

Remarks


No. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78.


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Item Motor current of mill D Motor bearing temperature of mill D Motor stator winding temperature of mill D Inlet primary air pressure of mill D Feed coal output of coal feeder D Inlet temperature of mill D Outlet temperature of mill D Primary air flow of mill E Inlet air pressure of mill E Outlet air pressure of mill E Differential pressure of mill E grinding roller Difference pressure of mill E Differential pressure of mill E grinding table Motor current of mill E Motor bearing temperature of mill E Motor stator winding temperature of mill E Inlet primary air pressure of mill E Feed coal output of coal feeder E Inlet temperature of mill E Outlet temperature of mill E Primary air flow of mill F Inlet air pressure of mill F Outlet air pressure of mill F Differential pressure of mill F grinding roller Differential pressure of mill F Differential pressure of mill F grinding table Motor current of mill F Motor bearing temperature of mill F Motor stator winding temperature of mill F Inlet primary air pressure of mill F Feed coal output of coal feeder F Inlet temperature of mill F Outlet temperature of mill F

Commissioning Company: Contractor：

Date:

Date:

Unit

Data


Dongfang Electric：

Remarks

Date: Date:

10.3

Appendix 3 Checklist of Dampers in Pulverized Coal System Checklist of Dampers in Pulverized Coal System KKS code

Name

X0HFE51AA001a X0HFE51AA001b X0HFE52AA001a X0HFE52AA001b X0HFE53AA001a X0HFE53AA001a X0HFE54AA001a X0HFE54AA001b X0HFE55AA001a X0HFE55AA001b X0HFE41AA001 X0HFE42AA001 X0HFE43AA001 X0HFE44AA001 X0HFE45AA001

Inlet air damper 1 of mill A Inlet air damper 2 of mill A Inlet air damper 1 of mill B Inlet air damper 2 of mill B Inlet air damper 1 of mill C Inlet air damper 2 of mill C Inlet air damper 1 of mill D Inlet air damper 2 of mill D Inlet air damper 1 of mill E Inlet air damper 1 of mill E Cold air damper of mill A Cold air damper of mill B Cold air damper of mill C Cold air damper of mill D Cold air damper of mill E

X0HFF11AA001

Outlet damper of mill A to corner 1

X0HFF12AA001

Outlet damper of mill A to corner 2

X0HFF13AA001 X0HFF14AA001 X0HFF21AA001 X0HFF22AA001 X0HFF23AA001

Outlet damper of mill A to corner 3 Outlet damper of mill A to corner 4 Outlet damper of mill B to corner 1 Outlet damper of mill B to corner 2 Outlet damper of mill B to corner 3

X0HFF24AA001

Outlet damper of mill B to corner 4

X0HFF31AA001 X0HFF32AA001

Outlet damper of mill C to corner 1 Outlet damper of mill C to corner 2


Remote Direction

Feedback

Operating time On Off(Close) (Opening)

Date

Result

Signature

Remarks

KKS code X0HFF33AA001 X0HFF34AA001 X0HFF41AA001 X0HFF42AA001 X0HFF43AA001 X0HFF44AA001 X0HFF51AA001 X0HFF52AA001 X0HFF53AA001 X0HFF54AA001 X0HFF11AA002 X0HFF21AA002 X0HFF31AA002 X0HFF41AA002 X0HFF51AA002 X0HFF12AA002 X0HFF22AA002 X0HFF32AA002 X0HFF42AA002 X0HFF52AA002

Name Outlet damper of mill C to corner 3 Outlet damper of mill C to corner 4 Outlet damper of mill D to corner 1 Outlet damper of mill D to corner 2 Outlet damper of mill D to corner 3 Outlet damper of mill D to corner 4 Outlet damper of mill E to corner 1 Outlet damper of mill E to corner 2 Outlet damper of mill E to corner 3 Outlet damper of mill E to corner 4 1#Corner A Layer Burner Inlet Pulverized Coal Damper 1#Corner B Layer Burner Inlet Pulverized Coal Damper 1#Corner C Layer Burner Inlet Pulverized Coal Damper 1#Corner D Layer Burner Inlet Pulverized Coal Damper 1#Corner E Layer Burner Inlet Pulverized Coal Damper 2#Corner A Layer Coal Damper 2#Corner B Layer Coal Damper 2#Corner C Layer Coal Damper 2#Corner D Layer Coal Damper 2#Corner E Layer

Burner Inlet Pulverized Burner Inlet Pulverized Burner Inlet Pulverized Burner Inlet Pulverized Burner Inlet Pulverized


Remote Direction

Feedback


Date

Result

Signature

Remarks

KKS code

X0HFF13AA002 X0HFF23AA002 X0HFF33AA002 X0HFF43AA002 X0HFF53AA002 X0HFF14AA002 X0HFF24AA002 X0HFF34AA002 X0HFF44AA002 X0HFF54AA002 X0HFW31AA001 X0HFW32AA001 X0HFW33AA001 X0HFW34AA001 X0HFW35AA001 X0HFE61AA002 X0HFE62AA002

Name Coal Damper 3#Corner A Layer Burner Inlet Pulverized Coal Damper 3#Corner B Layer Burner Inlet Pulverized Coal Damper 3#Corner C Layer Coal Damper 3#Corner D Layer Coal Damper 3#Corner E Layer Coal Damper 4#Corner A Layer Coal Damper 4#Corner B Layer Coal Damper

Burner Inlet Pulverized Burner Inlet Pulverized Burner Inlet Pulverized Burner Inlet Pulverized Burner Inlet Pulverized

4#Corner C Layer Burner Inlet Pulverized Coal Damper 4#Corner D Layer Burner Inlet Pulverized Coal Damper 4#Corner E Layer Burner Inlet Pulverized Coal Damper Seal air damper of mill A Seal air damper of mill B Seal air damper of mill C Seal air damper of mill D Seal air damper of mill E Outlet Seal Air damper of mill A Outlet Seal Air damper of mill B


Remote Direction

Feedback


Date

Result

Signature

Remarks

KKS code X0HFE63AA002 X0HFE64AA002 X0HFE65AA002 X0HFW21AA001 X0HFW22AA001

Name Outlet Seal Air damper of mill C Outlet Seal Air damper of mill D Outlet Seal Air damper of mill E Seal air damper of coal feeder A Seal air damper of coal feeder B

X0HFW23AA001

Seal air damper of coal feeder C

X0HFW24AA001

Seal air damper of coal feeder D

X0HFW25AA001

Seal air damper of coal feeder E

X0HFA10AA001 X0HFA20AA001

Emergency Unloading Coal Pipe Motorized Valve of coal feeder A

X0HFA30AA001

Emergency Unloading Coal Pipe Motorized Valve of coal feeder B Emergency Unloading Coal Pipe Motorized Valve of coal feeder C

X0HFA40AA001

Emergency Unloading Coal Pipe Motorized Valve of coal feeder D

X0HFA50AA001

Emergency Unloading Coal Pipe Motorized Valve of coal feeder E

X0HFB10GC001 X0HFB11GC001 X0HFB20GC001

Inlet Coal Gate of coal feeder A

outlet Coal Gate of coal feeder A Inlet Coal Gate of coal feeder B


Remote Direction

Feedback


Date

Result

Signature

Remarks

KKS code X0HFB21GC001 X0HFB30GC001 X0HFB31GC001 X0HFB40GC001 X0HFB41GC001 X0HFB50GC001 X0HFB51GC001 X0LBX70AA001 X0LBX70AA002


Name

Remote Direction

Feedback


outlet Coal Gate of coal feeder B Inlet Coal Gate of coal feeder C outlet Coal Gate of coal feeder C

Inlet Coal Gate of coal feeder D outlet Coal Gate of coal feeder D Inlet Coal Gate of coal feeder E outlet Coal Gate of coal feeder E Fire prevention steam valve of mill A Fire prevention steam valve of mill B

X0LBX70AA003

Fire prevention steam valve of mill C

X0LBX70AA004

Fire prevention steam valve of mill D

X0LBX70AA005

Fire prevention steam valve of mill E


Date:


Date:

Contractor：

Date:

Dongfang Electric:

Date:

Date

Result

Signature

Remarks

10.4

Appendix 4 Checklist of Control Dampers of Pulverized Coal System Checklist of Control Dampers of Pulverized Coal System KKS code

X0HFE41AA101 X0HFE42AA101 X0HFE43AA101 X0HFE44AA101 X0HFE45AA101 X0HFE51AA101 X0HFE52AA101 X0HFE53AA101 X0HFE54AA101 X0HFE55AA101 X0HFE51AA102 X0HFE52AA102 X0HFE53AA102 X0HFE54AA102 X0HFE55AA102

Name

0%

Feedback corresponding to ascending and descending instruction values 25% 50% 75% 100% 75% 50% 25% 0%

Date

Cold air control damper of mill A Cold air control damper of mill B Cold air control damper of mill C Cold air control damper of mill D Cold air control damper of mill E Hot air control damper of mill A Hot air control damper of mill B Hot air control damper of mill C Hot air control damper of mill D Hot air control damper of mill E Inlet Mixed air control damper mill A Inlet Mixed air control damper mill B Inlet Mixed air control damper mill C Inlet Mixed air control damper mill D Inlet Mixed air control damper mill E

of of of of of


Date:


Date:

Contractor：

Date:

Dongfang Electric：

Date:

Result

Signature

Remarks



PT.PLN(PERSERRO)

Owner’s DWG No.




Check Design

Date

Scale


DETAIL DESIGN STAGE

Procedure of Cold Ventilation and Air Measurement N/A

DWG No.


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A


Procedure of Cold Ventilation and Air Measurement

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Purpose ......................................................................................................................... 3

2.

Scope ............................................................................................................................. 3

3.

Preparation Basis......................................................................................................... 3

4.

Brief Description of System and Equipment ............................................................ 3

5.

Tools and Instrument for Commissioning................................................................. 3

6.

Prerequisite for Commissioning................................................................................. 4

7.

Measures for Commissioning Organization.............................................................. 5

8.

Machining and installation for air-flow measuring device ...................................... 6

9.

Commissioning Procedure .......................................................................................... 7

10.

Safety Measures ......................................................................................................... 11

11.

10.1

Safety Rules ©for Commissioning................................................................... 11

10.2


10.3


Appendix .................................................................................................................... 12 Appendix 1

Commissioning Condition Checklist.................................................... 13

Appendix 2

Layout plan on fabrication and installation for the temporary measuring

points 15 Appendix 3

Installation schematic diagram for the calibrated (checking) measuring

points of primary leveling and testing hole device at outlet of mill............................ 17 Appendix 4 Machining drawing for the temporary measuring points ..................... 18 Appendix 5 Record sheet on leveling test data for the pulverization pipe at outlet of coal mill ....................................................................................................................... 19 Appendix 6

Record sheet on calibrated test data for secondary airflow .................. 20

Appendix 7

Parameter record sheet for cold state ventilation test ........................... 21



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1.

Purpose

1.1

Under the condition of cold state, perform the complete dynamic check for the flue-gas and air system and all auxiliaries.

1.2

Calibrate each the primary and secondary airflow-measuring device.

1.3

Measure the airflow of primary air pipe at the inlet of each coal mill and level primary air pipe;

1.4

Inspect the installation condition and the oscillation test of the burner.

1.5

Inspect the correctness of each draft gauge.

2.

Scope This procedure is applicable for the ventilation and debugging under cold state for the boiler, the commissioning scope covers:

2.1

Overall dynamic inspection for each air damper and auxiliaries of the flue-gas and air system

2.2

Calibrate the airflow meter installed on the secondary air flue.

2.3

Calibrate the primary airflow meter at the inlet of each coal mill

2.4

Inspect and confirm each pressure meter of flue-gas and air system

2.5

Purge the furnace and air flue with great airflow under the cold state

2.6

Leveling test of the primary air

2.7

Inspect the installation condition and the oscillation test of the burner.

3.

Preparation Basis

3.1

Drawings of flue-gas and air system and coal pulverizing system;

3.2

Operating manual for the moving blade axial-flow fan;

3.3

Operating manual for the adjustable stationary blade axial-flow fan;

3.4

Operating manual for the centrifugal fan;

3.5

Operating manual for air preheater

4.

Brief Description of System and Equipment The boiler is equipped with two air preheaters, two induced draft fans, two forced draft fans and two primary fans. Refer to the relevant contents in the commissioning procedure of each fan for the specific parameters.

5.


5.1

Walkie talkie;

5.2

Pitot tube;

5.3

Digital multimeter;

5.4

Electronic anemometer;



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5.5

Electronic micromanometer;

5.6

U- pipe, ruler, latex tube, marking pen and adhesive tape

6.


6.1

Installation is completed and records are complete.

6.2

The operators in the main post and auxiliary post are arranged completely with qualified training.

6.3

The identification of equipments and valves are complete and correct.

6.4

The road of the site is smooth with adequate lighting.

6.5

The communication equipments are sufficient in quantity and can be employed.

6.6

The wiring of electric motor is favorable and its insulation is qualified.

6.7

The installation and calibration for I&C and electrical meter are complete; the meter can be put into operation.

6.8

The commissioning for the subsection of air preheater is completed; the air preheater can be put into operation.

6.9

The commissioning for the subsection of each fan is completed; the air preheater can be put into operation.

6.10

DCS system is provided with the operation condition on CRT.

6.11

The installation for coal mill system is complete, providing with ventilation condition

6.12

The inspection for the related air damper is completed, with normal commissioning.

6.13

The machining and installation for the measuring hole for test is completed, with correct location.

6.14

The setting up for test platform is completed, being safe and reliable;

6.15

The installation for all the air flues of flue-gas and air system is completed. The inner should be cleared cleanly;

6.16

The furnace, air flue and the manhole of coal mill have been closed uniformly;

6.17

The slag hopper at the bottom of the boiler should cleared cleanly, the boiler bottom can be sealed.

6.18

The commissioning for the lubrication oil system and hydraulic oil system is completed, providing with commissioning condition.

6.19

The cooling system of the auxiliaries can be put into operation normally.

6.20

The motive power can be put into operation reliably;

6.21

The test on logic, protection and alarm for the flue-gas and air system is completed, with qualified results.


7.


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7.1

7.2

7.3



◆


◆


◆


◆


◆


◆




◆


◆


◆


◆

Be responsible for machining of measuring holes for test and setup of test platform;

◆



7.4

7.5




◆


◆


◆


◆


Responsibilities of Dongfang Electric


7.6


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◆


◆


◆


◆




◆


◆


8.

Machining and installation for air-flow measuring device

8.1

Selection for the locations on calibration and verification In order to calibrate (verify) correctly, the calibration points (verification points) have specific requirements on around location; in principle, they must meet: the straight length in front of the calibrating points is 4-7 times of the diameter of pipeline (equivalent diameter) and the straight length in the rear of calibration points is 1-2 times of the diameter of pipeline (equivalent diameter). For the rectangle channel, the straight length in the rear of calibration points is 2-3 times of the diameter of pipeline (equivalent diameter). If the site condition cannot be met, the calibration error can be large; the Owner must agree the location selected.

8.2

8.3

Machining and installation for the calibration stand at the location of calibration points for secondary hot air flow device (1)

2 airflow-measuring devices are set on the rectangle section with 4200X3000X4 of the left and right secondary hot air chambers.

(2)

The calibration hole stand for the airflow device should be installed at the place of rectangle section with 4200X3000X4 of the secondary hot air chamber and in front of the airflow device. The installation location for the hole stand is located at the position calculated according to the rectangle principle of grid. 8 plug seats are required to be installed on the cross section selected. 16 plug seats are required on both sides.

(3)

The specific location shall be designated on site. The identical level should be kept basically for installation of all the hole stands. Opening shall be conducted in a manner of easy insertion and push-out of instrument and apparatuses.

(4)

8 hole stands calibrated are required to be installed on each side of rectangular section, 16 plug seats are required to be machined totally on both sides.

The installing location for the calibration stand of the primary air calibration points at outlet of each coal mill and the verification stand at inlet of the burner: (1)

5 coal mills are provided totally for the boiler, 4 pieces of primary air and pulverized coal pipelines with 480×10 are set at outlet of each cola mill, 20 pieces in total.

(2)

The leveling hole stand for primary air and pulverized coal pipelines is set at 2-3m in the rear of contraction hole; a hole is excavated respectively at X\Y direction of calibration point pipeline, there are not the shelters in front of hole. All the hole stands keep in the identical level and in the same side, opening shall be conducted in a manner



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of easy insertion and push-out of instrument and apparatuses. It is required to fabricate 40 primary air and pulverized coal pipeline leveling plug seats. The specific is designated on site.

8.4

(3)

The checking pore seat for the primary air and pulverized coal pipeline should be established at 4-5m in front of burner, a hole should be opened respectively at X/Y direction of the pipeline section of fixed points, there is free of the barricade in front of the hole, all the hole seats remain in the identical horizontal height, opening shall be conducted in a manner of easy insertion and push-out of instrument and apparatuses. The test platform should also be set up. It is required to fabricate 40 checking plug seats for the primary air and pulverized coal pipeline. The specific is designated on site.

(4)

Therefore, 80 leveling and checking plug seats for the primary air and pulverized coal pipeline are required to be fabtricated.

(5)

There are 6 sets of backrest pipes used for leveling, including 2 sets of standby ones. It is required that the outer threads against the backrest pipes are matched with the inner thread of the plug seat. The site location should ensure the convenient installing and fetching for the backrest pipes.

Installation location for the seat of fixed point for the flow devices at inlet of each coal mill: (1)

One airflow-measuring device is provided at the rectangular section with 1250X1250X4 of each inlet of mill for the boiler. There are 5 airflow devices totally.

(2)

The fixed hole seat for the airflow device is provided at the rectangular section with 1250X1250X4 of each inlet of mill for the boiler and in front of the airflow device. The installing location of the hole seat is located on the location calculated according to the equal rectangle principle of grid. 5 plug seats are required to be installed on the selected section and 25 plug seats are required totally on both sides.

(3)

The specific location is designed on site. All the hole seats remain in the identical horizontal height basically, the opening direction should ensure that the instrument equipments can be inserted and pushed out conveniently.

(4)

5 fixed hole seats are required to be installed for the rectangle section of each mill. 25 plug seats are required to be fabricated totally for five mills.

8.5

Fabrication and layout drawing: the backrest pipe fabrication drawing (including the leveling and checking plug seats for the primary air-powder pipe),the fabrication drawing for the primary plug seat of the secondary hot air and the inlet of coal mill is identical to the leveling plug seat of the primary air-powder pipe. 121 pieces are fabricated totally (with 121 drain plugs and plug seats respectively). 6 backrest pipes are fabricated.( referring to the machining and layout drawing for temporary measuring points in appendix 2,3,4,5).

9.


9.1

Inspection prior to each fan start-up (1)

The installation and maintenance work for each air preheater, induced draft fan, forced draft fan, sealed fan, primary fan and the coal mill are completed. The inner of air flue should be cleared cleanly, all the staff inside the air flue has withdrawn entirely. All the manholes are sealed.

(2)

The trench cover plates in the periphery of each fan should be covered completely, the related temporary scaffolds are dismantled. Roads are free of obstructions. Lighting is adequate.


9.2

9.3


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Page 8 of 24

(3)

The anchor bolts for each fan and motor are complete and secured properly.

(4)

The oil level for the oil tank of each fan (or the bearing box) should be normal and visible; the oil quality should be favorable.

(5)

The inlet and outlet valves for each fan are closed; the actuators of each damper and damper plate are connected properly.

(6)

The cooling system for each fan and motor is normal.

(7)

All the dampers for flue-gas and air system should be inspected completely and operated normally.

(8)

All the dampers for coal-pulverizing system should be inspected completely and operated normally.

(9)

The installation for testing points on test is completed and the setting up for the test platform is completed, both of them conform to the test requirement.

Flue gas and air start-up (1)

Program startup of the air preheater on side of A and B.

(2)

Program startup of the induced draft fan on side of A and B

(3)

Program startup of the forced draft fan on side of A and B

(4)


(5)


Purging the furnace with great airflow After flue gas and air is started normally, the negative pressure for the furnace is remained, the openness of the forced draft fan is adjusted up to around 50-70%, and the great airflow is employed to purge the furnace. The purging time is 30 minutes. During operating of fan, the dedicated personnel should be assigned to monitor each fan and the conditions for the fan vibrating and temperature varying should be noticed.

9.4

Related meter on operation of flue-gas and air system After the purging is completed, the related meters for air pressure and airflow are put into operation The load of fan is changed to observe the variation condition of meter, the invariable condition and the condition that has obvious error variation should be disposed timely.

9.5

Calibration for the measuring devices of the secondary airflow Under the working condition that the openness of damper at inlet of forced draft fan is 45%, 65% and 90%, the calibration for measuring equipments of the secondary airflow at various layers on both sides of A and B is performed respectively. The measuring result is filled into the table below:

Working condition Secondary airflow on A side (computer)

Working condition I

A side

B side

Working condition II

A side

B side

Working condition III

A side

B side



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Secondary airflow on A side (actual measuring ) Secondary airflow on B side (computer) Secondary airflow on B side (actual measuring ) The calibration result is filled into the table below: Measuring point location Coefficients

Secondary airflow on the A side

Secondary airflow on the B side

Coefficients of working condition I Coefficients of working condition II Coefficients of working condition III Average coefficient

9.6

(1)

Two forced draft fans are adjusted and the moving blades are set in 45%, 65% and 90% (provisionally); the damper of the air induced draft fan should be adjusted to keep the negative pressure of furnace in the normal scope; the wind velocity indicator is employed to measure the wind speed in different locations for the measuring points of the secondary wind box.

(2)

The airflow measured actually is compared with the data from the computer DAS to inspect the secondary airflow; if there is the deviation, the amendment should be performed timely.

(3)

The deviation of the airflow on both sides is compared. If the deviation is greater, the current of two fans should be compared; if there is the deviation, the equivalent current should be adjusted, and then the airflow can be compared; if the deviation is still greater, it is required to inspect the air damper and the airflow device.

(4)

The dampers for two forced draft fans are adjusted to ensure the current of motor is adjacent to the rated current; the airflow should be measured to inspect whether the air output meets the air output required when the boiler is in the maximal load.

Calibration for the measuring device of primary airflow at inlet of each coal mill and leveling for the primary air (1)

Starting the sealing fan and opening the sealing damper

(2)

Starting two (or one) primary fans

(3)

Open the outlet coal valve of the mill measured, cold and heat damper as well as the manual paddle valve at inlet of each burner. The negative pressure of furnace is remained; adjust two primary fans; the guide blade is set on 50%, 70% and 90% respectively; the damper of air-induced fan is adjusted to keep the normal negative pressure of furnace and stable load of fan; the wind velocity indicator is employed to measure the primary airflow at inlet of coal mill and the wind speed of each pulverized coal pipeline, the measuring device of the primary air at inlet of coal mill is calibrated. Note: if the measuring point location is short in front and back of the airflow device at inlet of coal mill and when the calibration points fail to meet the requirement of



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calibration, the error will be greater. The primary airflow device at inlet of calibrated coal mill is installed in reverse on 4 pieces of primary air and pulverized coal pipelines to reduce the error. When calibrating the airflow of the coal mill, the hot air valve and the cold air valve at inlet of coal mill are opened to adjust the load of primary fan and measure the airflow at inlet of coal mill. (4)

The wind speed for the pulverized coal pipeline is measured whether to be within the design scope. The wind speed for the pulverized coal pipeline is ensured to reach the design value and compute the deviation of the wind speed for the pulverized coal pipeline, if the deviation is greater ( it is required that the deviation of the wind speed on each piece of primary air duct is equal to or less than ±5% for the one of the average value for the primary air duct), the contraction cavity on the primary air duct is required to be adjusted and installed to remeasure and recalculate until it is qualified.

(5)

Airflow computing, the airflow for 4 pieces of on pulverized coal pipeline for each coal mill is added to compare with the airflow at inlet of coal mill acquired from DAS system and check the primary air flow at inlet of mill, if deviation exists, the correction should be made timely.

The measurement result is filled into the table below: Working condition Measuring point location

Working condition I



Airflow at inlet of A mill (computer) Airflow measured actually at inlet of mill A (revision ) Airflow at inlet of B mill (computer) Airflow measured actually at inlet of mill B (revision ) Airflow at inlet of C mill (computer) Airflow measured actually at inlet of mill C (revision ) Airflow at inlet of mill D (computer) Airflow measured actually at inlet of mill D (revision ) Airflow at inlet of mill E(computer) Airflow measured actually at inlet of mill E (revision ) Calibration coefficients for the airflow at inlet of coal mill Location of measuring points Coefficients Coefficients of working condition I

Mill A

Mill B

Mill C

Mill D

Mill E



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Coefficients of working condition II Coefficients of working condition III Average coefficients 9.7 9.7.1

9.7.2

Cold state inspection and oscillation test for the burner Entering into the furnace and inspecting the burner (1)

The oscillation bearing place of the nozzle is inspected whether to be perfect, the bolts of axial load cap are inspected whether to be lost or loosen and the nozzles are inspected whether there is sufficient oscillation space in the nozzle and whether the jam is provided.

(2)

Inspecting the location of the impeller for the protrusion of oil gun;

(3)

Inspecting the protrusion location of the igniting gun;

(4)

The nozzle should be inspected to be in the horizontal state.

(5)

If the nozzle is not located in the horizontal position, the bolts should be employed to adjust it.

(6)

After the nozzle is leveled, the zero correction for indication of the oscillation pointer outwardly should be performed.

Cold state oscillation test (1)

Oscillating up and down can be realized easily.

(2)

The horizontal location of nozzle is correct and the oscillation of each nozzle is synchronous.

(3)

The indication for nozzle oscillation is consistent with the indication for the pointer of oscillation mechanism outwardly. The accuracy for indication of point is employed to confirmed it .

9.8

Complete trial operation record: refer to appendix 8 for the main parameters for commissioning starting.

10.

Safety Measures

10.1

Safety rules for Commissioning

10.1.1


10.1.2


10.1.3


10.2




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Rotating equipment Injuries might be caused by rotating equipment during commissioning or test. Therefore, special care must be taken during work and do not touch the rotating components with tools or your hand.

10.2.2

The safety helmet is worn or is not employed properly; When adjusting or testing, the strike is produced possibly by the objects to cause the injuries and deaths. When approaching the production site, the safety helmet should be worn properly and the belts of safety helmet should be tied properly. The danger of falling objects above and around the operation region is inspected.

10.2.3

The setting up for the temporary test platform and scaffolds does not conform to the stipulation. The personnel injury is produced. Prior to working, after the scaffold or the platform is inspected to be qualified, the racking work can be performed.

10.2.4

The safe protective facilities are not set or the safe protective facilities are incomplete. The personnel injury is produced. Prior to working, after the setting for the safe protective facilities is set properly, the work can be performed.

10.3


10.3.1

The operators should carefully supervise the counting to ensure that the working condition for the test is stable, and the patrolling inspection for the operating equipment and system should be strengthened.

10.3.2

The variation of parameters for oil pressure, oil temperature, the temperature of bearing and vibration should be supervised to avoid producing the bearing burn-out accident.

11.

Appendix



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Items

Requirements

Result

1

System installation

Installation are completed and records are complete

□Yes □No

2

Operators in the main position and the auxiliary position

The allocation is complete and the training is qualified;

□Yes □No

3

Identification of equipment

The identification is complete and correct.

□Yes □No

4

Field condition

Clear road, sufficiency of illumination

□Yes □No

5


Sufficient and usable

□Yes □No

6

Electric motor

Correct wiring and earthing

□Yes □No

7

I&C and electrical gage

The installation check is completed, the commissioning can be made

□Yes □No

Air preheating system

The commissioning for the individual equipment and system is completed, the commissioning can be made

□Yes □No

9

All fan systems

The commissioning for the individual equipment and system is completed, the commissioning can be made

□Yes □No

10

DCS system

Providing with the operation conditions on CRT

□Yes □No

11

Coal mill system

The installation is completed and the ventilation condition is provided.

□Yes □No

12

Related damper

The inspection is completed, the commissioning is normal.

□Yes □No

13

Measuring holes for test

The fabrication and installation are completed and the location is correct.

□Yes □No

14

Test platform

The setting up is completed safely and reliably.

□Yes □No

15

All the air flues for the flue-gas and air system

The installation is completed and the inner is cleared cleanly.

□Yes □No

8

Verified by

Remar ks



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16

Furnace, air flue and the manhole of cola mill

Closed uniformly

□Yes □No

17

Sundries in the refuse vessel of furnace bottom

Cleared cleanly and closed tightly

□Yes □No

18

Lubrication and hydraulic oil system of auxiliaries

The commissioning is completed, and it is ready for operation

□Yes □No

19

Cooling water system of auxiliary engine

Can be put into operation normally

□Yes □No

20

Power supply

Can be put into operation reliably

□Yes □No

21

Logic, protection and alarm for flue-gas and air system

The test is completed and the result is qualified.

□Yes □No


Contractor:

Date:

Date:


Dongfang Electric

Date:

Date:



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Appendix 2 Layout plan on fabrication and installation for the temporary measuring points Central location of the calibration point and the measuring point for the air -flue flow device at inlet of boiler mill

124.

248

248

248

248

12

1250mm,(distance between the inner wall of air flue)

1250mm (distance between the inner walls of air flue

Calibrated measuring points for the airflow of hot air duct at inlet of mill Schematic Diagram for central location

Remarks (1)

There is one airflow device at the inlet hot air duct of each mill, there are 5 airflow devices totally at inlet of 5 mills.

(2)

The size of pipeline at the calibration points: 1250×1250×4mm, 5 measuring point holes are opened on the identical cross section for the horizontal location of pipeline. The distance between the centers of the two measuring point holes is 248.4mm; the distance of the measuring points at the furthest edge apart from the pipe wall is 124.2mm. 25 calibrated plug seats and plugs are required totally.

(3)

The commissioning and installation for the opening location of the specific measuring points are designated on site.

(4)

50 plug seats and plugs are required to be machined totally for 2 boilers.



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Appendix 2 (continued) Central location of the calibration point and the measuring point for secondary hot air -flue flow device of boiler

262

52

52

52

52

52

52

52

262

3000mm (distance between the inner wall of air flue)

4200mm (distance between the inner wall of air flue)

Calibrated measuring points for the secondary hot air flue Schematic Diagram for central location

Remarks (1) There is one airflow device at the hot air duct on the left and right of boiler secondary air, there are 2 airflow devices totally. (2) The size of pipeline at the calibration points: 4200×3000×4mm, 8 measuring point holes are opened on the identical cross section for the horizontal location of pipeline. The distance between the centers of the two measuring point holes is 524mm; the distance of the measuring points at the furthest edge apart from the pipe wall is 262mm. 16 plug seats and plugs are required totally. (3) The commissioning and installation for the opening location of the specific measuring points are designated on site. (4) 32 plug seats and plugs are required to be machined totally for 2 boilers.



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Appendix 3 Installation schematic diagram for the calibrated (checking) measuring points of primary leveling and testing hole device at outlet of mill

Primary hot air duct

Primary air Φ480×10

Remarks (1) 2 orthogonal measuring-point holes are opened on the identical transverse section in the horizontal pipeline section. (2) 2 calibrated plug sets are installed at outlet of each mill and 2 calibrated plug seats are installed at inlet of burner. (3) It is required that the length of the straight pipe section is greater than 4D and then greater than 2D, in addition, it is noticed that there are not barriers at 10m of the right forward and right above to ensure that the instruments can be inserted and extracted conveniently. (4) The commissioning and installation for the opening location of the specific measuring points are designated on site. The test platform is required to be set up in the entire locations of measuring points. (5) 4X20=80 plug seats and plugs are required for the primary air flue. 6 sets of backrest pipes are machined. (6) 160 plug seats and plugs are required to be machined totally for 2 boilers. 6 sets of backrest pipes are machined.



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Appendix 4 Machining drawing for the temporary measuring points

PLTU 1 Jatim-Pacitan（2×315MW） Project Procedure of Cold Ventilation and Air Measurement

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Appendix 5 Record sheet on leveling test data for the pulverization pipe at outlet of coal mill Measuring point Measuring Measuring Measuring point Measuring point Measuring point Confirm Remarks 1 (in/out) point 2 (in/out) point 3 (in/out) 4 (in/out) 5 (in/out) 6 (in/out) ed by:

No.

Coal mill A

Coal mill B

Coal mill C

Coal mill D

Coal mill E

#1 primary air duct #2 primary air duct #3 primary air duct #4 primary air duct #1 primary air duct #2 primary air duct #3 primary air duct #4 primary air duct #1 primary air duct #2 primary air duct #3 primary air duct #4 primary air duct #1 primary air duct #2 primary air duct #3 primary air duct #4 primary air duct #1 primary air duct #2 primary air duct #3 primary air duct #4 primary air duct


REV A


Page 20 of 24


Appendix 6 Record sheet on calibrated test data for secondary airflow No.





Measuring hole 1 Measuring hole 2 Measuring hole 3 Measuring hole 4 Measuring hole 5 Measuring hole 6 Measuring hole 7 Measuring hole 8 Measuring hole 9 Measuring hole 10 Measuring hole 11 Measuring hole 12 Commissioning Contractor:

Contractor:

Date:

Date:


Dongfang Electric

Date:

Date:



Confirm ed by:

Remar ks


REV A


Page 21 of 24


Appendix 7 Parameter record sheet for cold state ventilation test No.

Item

Unit

1

Furnace draft

2

Temp. of flue gas

3

Openness for moving blade of forced draft fan（A/B）

4

Current of forced draft fan （A/B）

5

Outlet pressure of forced draft fan （A/B）

6

Differential pressure of forced draft fan

7

Vibration of forced draft fan bearing

8

Air temperature of inlet on side of secondary air box

9

Secondary air temperature at (A/B）

outlet of air preheater

10

Secondary air temperature at (A/B）

inlet of air preheater

11

Bearing temperature of forced draft fan （A/B）

12

Secondary air pressure at (A/B）

13

Secondary air differential pressure at air preheater (A/B）

14

Differential pressure on side A of furnace/secondary air

outlet of air preheater inlet/outlet of

Working condition I



Working condition IV

Confirme d by:

Remarks


REV A


Page 22 of 24


box 15

Differential pressure on side B of furnace/secondary air box

16

Air pressure on side of secondary air box

17

Airflow 1 on side of secondary air box

18

Air temperature of inlet on side of secondary air box

19

Airflow 1 on side of secondary air box

20

Inlet air temperature of forced draft fan（A/B）

21

Outlet air temperature of forced draft fan（A/B）

22

Motor bearing temperature of forced draft fan

23

Coil temperature for motor for the forced draft fan （A/B）

24

Primary air fan guide blade opening (A/B)

25

Primary air fan current (A/B)

26

Primary air fan outlet pressure (A/B)

27

Differential pressure of primary fan （A/B）

28

Bearing vibration of primary fan （A/B）

29

Primary air temperature at outlet of air preheater

30

Primary air temperature at outlet of air preheater A/B）

31

Temperature of primary air fan bearings (A/B)

32

Primary air pressure at outlet of air preheater A/B）


REV A


Page 23 of 24


33

Primary air differential pressure of air preheater

34

Primary air fan inlet pressure (A/B)

35

Primary air fan outlet pressure (A/B)

36

Temperature of primary air fan motor bearings (A/B)

37

Temperature of primary air fan motor windings (A/B)

38

A ID fan moving blade opening

39

B ID fan moving blade opening

40

A ID fan current

41

B ID fan current

42

A ID fan inlet air pressure

43

B ID fan inlet air pressure

44

Outlet/inlet pressure difference of A ID fan

45

Outlet/inlet pressure difference of B ID fan

46

A ID fan bearing vibration

47

B ID fan bearing vibration

48

A ID fan bearing temperature

49

B ID fan bearing temperature

50

A ID fan motor bearing temperature

51

B ID fan motor bearing temperature

52

Primary air volume of Mill A

53

Inlet air pressure of Mill A


REV A


Page 24 of 24


54

Outlet/inlet pressure difference of Mill A

55

Primary air volume of Mill B

56

Inlet air pressure of Mill B

57

Outlet/inlet pressure difference of Mill B

58

Primary air volume of Mill C

59

Inlet air pressure of Mill C

60

Outlet/inlet pressure difference of Mill C

61

Primary air volume of Mill D

62

Inlet air pressure of Mill D

63

Outlet/inlet pressure difference of Mill D

64

Primary air volume of Mill E

65

Inlet air pressure of Mill E

66

Outlet/inlet pressure difference of Mill E


Contractor:

Date:

Date:


Dongfang Electric

Date:

Date:



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-M-01-GCC-001 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI


Check Design Scale


DETAIL DESIGN STAGE

Procedure of Air Compressor System N/A

DWG No.


REV

A

Table of Contents

1.

PURPOSE .................................................................................................................................... 3

2.

SCOPE ......................................................................................................................................... 3

3.


4.


5.

TOOLS AND INSTRUMENT FOR COMMISSIONING........................................................... 3

6.


7.


8.


9.

SAFETY MEASURES .............................................................................................................. 10

9.1


9.2

Personal Risk and Preventative Measures....................................................... 10

9.3


10.

APPENDIX................................................................................................................................ 11

10.1


10.2

Appendix 2

Instrument Air Compressor Valve Record................................. 13

1.

Purpose

1.1

To check if logic of air compressor system is correct.

1.2

To check if air compressor system works properly through trial run.

1.3

To facilitate air compressor system working properly through regulation in trial run; to satisfy start-up and stop requirement of unit and guarantee unit running securely and stably.

2.

Scope This Procedure applies to commissioning of air compressor systems, including regulation and trial run of air compressor and drier.

3.

Preparation Basis

3.1

Technical agreement of air compressor;

3.2

Technical file of air compressor;

3.3

Operating manual of air compressor.

4.


4.1

Three instrument air compressors, two in operation while one in standby mode; two service air compressors, one in operation while one in standby mode, which can supply air to instrument air compressor system.

4.2

Technical parameters of air compressor Air compressor

4.3

Mating motor

Model

SA-120W

Model

Y315M-2FGB35

Air displacement

3

21m /min

Power

125KW

Max. operating pressure

0.8MPa

Voltage

380V

Shaft power

125KW

Current

257A

Working ambient temperature

≤40℃

Rotation speed

2975rpm

Technical parameters of air filter Oil removal filter

Rear filter

Front filter

Operating pressure

0.8MPa

Operating pressure

0.85 MPa

Operating pressure

0.8MPa

Working temperature

100℃

Working temperature

100℃

Working temperature

100℃

Medium

Air

Medium

Air

Medium

Air

3

3

Volume

0.058 m

Volume

0.058 m

Volume

0.058 m3

Filtration rating

0.01μm

Filtration rating

0.1μm

Filtration rating

0.1μm

5.


5.1

Walkie talkie;

5.2


5.3

Digital multimeter.

6.

Prerequisite for Commissioning Before formally beginning commissioning job system by system, commissioning persons should conduct comprehensive checks on conditions that should be available for commissioning of this system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and make well the records.

6.1

Equipments and systems have been installed in accordance with requirements. They are qualified according to result of check. Installation record is complete.

6.2

Air compressor has passed through trial run individually.

6.3

Monitoring instruments and gauges within the system are complete. Temperature and pressure sensors have been subject to C&I commissioning and are qualified and their actions are free and reliable.

6.4

Tools and apparatuses for trial run of the system have been prepared.

6.5

Field of trial run site is level, passage is clear and lighting is sufficient. Trench covers inside compressor room have been mounted.

6.6

There are no inflammable and explosive substances on the site. Fire-fighting apparatus are in readiness.

6.7

Check settings of running parameters (which are set up before delivery).

6.8

Check if electrical connection is safe and reliable.

6.9

Check if oil level in oil separator is proper.

6.10

Check if cooling water pipe is opened.

6.11

Check if steam vent valve is opened.

6.12

Check if tools and material are complete in types and adequate in quantity.

6.13

Get running tools and record sheets ready.

6.14

Get commissioning tools, instruments and apparatuses ready.

6.15

All gauges of the system are complete, calibrated and qualified.

7.


7.1



◆


◆


◆


◆


◆


◆ 7.2

7.3



◆


◆


◆


◆



7.4

7.5

7.6





◆


◆


◆


◆

Be responsible for dealing with the accidents occurred in commissioning



◆


◆


◆


Responsibilities of Project Owner ◆


◆


◆


8.


8.1

Cold check and transmission test of valve Check the motorized valves and enter the following data on the records: KKS code, designation, local position indication, remote operating direction and feedback, operating (on and off) time of valve, test date, signature of commissioning contractor. Refer to Appendix 2 for the record sheet.

8.2

Check of Interlock Protection and Alarms (Note: Interlock protection test items are to be determined by result of logic discussion.)

8.2.1

Place power supply of air compressor on test position and check following items: （ 1 ） Start air compressor from computer. Feedback on computer shall be correct. （ 2 ） Shut down air compressor from computer. Feedback on computer shall be correct. （ 3 ） Emergency button shall work reliably.

8.2.2

Interlock protection test of air compressor and system

No.

Test item

Fixed value

Start, stop, interlock and alarm of instrument air compressor Instrument air compressor A

(1)

Instrument air compressor A, started and stopped via PLC

(2)

Emergency stop of instrument air compressor A

(3)

Electric (overload) protection of instrument air compressor A, PLC flash alarm

(4)

Protection for water outage (less than 9 t/h) in instrument air compressor A, PLC flash alarm

(5)

Protection for air temperature at outlet of instrument air compressor A higher than 100℃, PLC flash alarm

(6)

Unloading for pressure at outlet of instrument air compressor A higher than 0.80MPa, PLC flash alarm

(7)

Loading on for pressure at outlet of instrument air compressor A less than 0.65MPa, PLC flash alarm

Instrument air compressor B (1)

Instrument air compressor B, started and stopped via PLC

(2)

Emergency stop of instrument air compressor B

(3)

Electric (overload) protection of instrument air compressor B, PLC flash alarm

(4)

Protection for water outage (less than 9 t/h) in instrument air compressor B, PLC flash alarm

(5)

Protection for air temperature at outlet of instrument air compressor B higher than 100℃, PLC flash alarm

(6)

Unloading for pressure at outlet of instrument air compressor B higher than 0.79MPa, PLC flash alarm

(7)

Loading on for pressure at outlet of instrument air compressor B less than 0.65MPa, PLC flash alarm

Instrument air compressor C (1)

Instrument air compressor C, started and stopped via PLC

(2)

Emergency stop of instrument air compressor C

(3)

Electric (overload) protection of instrument air compressor C, PLC flash alarm

(4)

Protection for water outage

(less than 9 t/h) in

Results

Remarks

instrument air compressor C, PLC flash alarm (5)

Protection for air temperature at outlet of instrument air compressor B higher than 100℃, PLC flash alarm

(6)

Unloading for pressure at outlet of instrument air compressor C higher than 0.79MPa, PLC flash alarm

(7)

Loading on for pressure at outlet of instrument air compressor C less than 0.65MPa, PLC flash alarm

Service air compressor A (1)

Service air compressor started and stopped via PLC

(2)

Emergency stop of service air compressor

(3)

Electric (overload) protection compressor, PLC flash alarm

(4)

Protection for water outage (less than 9 t/h) in service air compressor, PLC flash alarm

(5)

Protection for air temperature at outlet of service air compressor higher than 100℃, PLC flash alarm

(6)

Unloading for pressure at outlet of service air compressor higher than 0.79MPa, PLC flash alarm

(7)

Loading on for pressure at outlet of service air compressor lower than 0.65MPa, PLC flash alarm

of

service

air

Service air compressor B (1)

Service air compressor started and stopped via PLC

(2)

Emergency stop of service air compressor

(3)

Electric (overload) protection compressor, PLC flash alarm

(4)

Protection for water outage (less than 9 t/h) in service air compressor, PLC flash alarm

(5)

Protection for air temperature at outlet of service air compressor higher than 100℃, PLC flash alarm

(6)

Unloading for pressure at outlet of service air compressor higher than 0.79MPa, PLC flash alarm

(7)

Loading on for pressure at outlet of service air compressor lower than 0.65MPa, PLC flash alarm

of

service

air

Interlock between instrument air compressors (1)

When instrument air compressor A and B are running, if any one trips due to failure, instrument air compressor C will be interlock-started.

(2)

When instrument air compressor A and B are running, if pressure in header is low-low, instrument air compressor C will be interlock-started.

(3)

When instrument air compressor B and C are running, if any one trips due to failure, instrument air compressor A will be interlock-started.

(4)

When instrument air compressor B and C are running, if pressure in header is low-low, instrument air

compressor A will be interlock-started. (5)

When instrument air compressor A and C are running, if any one trips due to failure, instrument air compressor B will be interlock-started.

(6)

When instrument air compressor A and C are running, if pressure in header is low-low, instrument air compressor B will be interlock-started.

Interlock between service air compressors (1)

When service air compressor A is running, if any one trips due to failure, service air compressor B will be interlock-started.

(2)

When service air compressor A is running, if pressure in header is low-low, service air compressor B will be interlock-started.

(3)

When service air compressor B is running, if any one trips due to failure, service air compressor A will be interlock-started.

(4)

When service air compressor B is running, if pressure in header is low-low, service air compressor A will be interlock-started.

Interlock between driers (1)

When drier A and B are running, if any one trips due to failure, drier C will be interlock-started.

(2)

When drier B and C are running, if any one trips due to failure, drier A will be interlock-started.

(3)

When drier A and C are running, if any one trips due to failure, drier B will be interlock-started.

(4)

After drier A starts and runs for 1 min, if pneumatic valve at corresponding outlet is not opened, drier A will be interlock-stopped.

(5)

After drier B starts and runs for 1 min, if pneumatic valve at corresponding outlet is not opened, drier B will be interlock-stopped.

(6)

After drier C starts and runs for 1 min, if pneumatic valve at corresponding outlet is not opened, drier C will be interlock-stopped.

Motorized valve A at outlet of service air compressor (1)

If any one of service air compressors starts and runs, motorized valve A will be interlock-opened (3s pulse).

Motorized valve B at outlet of instrument air compressor (1)

If any one of instrument air compressors is running and pressure at the compressor outlet is low and any one of service air compressors is running, motorized valve B will be interlock-opened (3s pulse).

8.3

Startup procedure of air compressor

8.3.1

Make preparation for the first startup (including the work that cooperate manufacturer to

carry out protection test of single equipment and the test result shall be passed.) 8.3.2

Jog motor to check its rotation direction.

8.3.3

Start air compressor and allow it run for 8 hours.

8.3.4

Open the stop valve on air delivery pipe to check if there is leakage in pipe.

8.3.5

Close stop valve gradually to check if unloading pressure is identical with the recommended on nameplate.

8.3.6

Check running temperature. Check cooling system and ambient condition if running temperature is higher than 95℃.

8.3.7 8.4

Shutdown of air compressor Operation and maintenance of air compressor Before start air compressor, check oil level. If oil level is too low, add lubrication oil. After start air compressor, check if all indications are correct. Check operating conditions of all systems and check if there is leakage and abnormal noise.

8.5

Settings of running parameters of air compressor:

8.5.1

Water inlet temperature≤30℃, water inlet pressure: 0.2 ～ 0.5 MPa

8.5.2

Pressure range of air flow regulation system: 0.21 ～ 0.76 MPa

8.5.3

Differential pressure between inlet and outlet of separator: 0.03≤ΔP1≤0.07MPa

8.5.4

Air discharge pressure of compressor: 0.65≤P ≤0.79MPa

8.6

Startup procedure of drier:

8.6.1

Make preparation for startup.

8.6.2

Check power supply, voltage and phase, compressed air temperature and pressure at inlet of drier.

8.6.3

It is important to close inlet valve and outlet valve of drier before commissioning. Open bypass valve to allow compressed air bypass for 2 hours at least so as to blow out impurities in piping.

8.6.4

Close inlet and outlet valves of drier when air tight test and pressure test of piping are being conducted.

8.6.5

Purge by the drier. Close and inlet and outlet valves. Start desiccant dryer, then open inlet valve and pressurize piping inside drier. Open outlet valve gradually to vent.

8.6.6

Dry by the drier. Start drier and close outlet valve. Open inlet valve. Open regulating valve of purge air flow of desiccant dryer fully. Increase purge air flow to dry air for several hours.

8.7

Drier commissioning

8.7.1

Startup procedure: Open inlet valve and close outlet valve. Start drier, then open outlet valve slowly.

8.7.2

Shutdown procedure: Close outlet valve. Cut off power supply, then close inlet valve.

8.7.3

Dismantle air filter element before pressure test and trial run and take care of it. Reinstall it after trial run.

8.8

Items to be adjusted during commissioning

8.8.1

Verification of safety valve and check of air tightness;

8.8.2

Adjustment of unloader and water drain of air compressor;

8.8.3

Interlock protection alarm test of system;

8.8.4

Adjustment of cooling water flow and temperature;

8.8.5

Purge of header piping;

8.8.6

Adjustment of running mode of system. （1）

Standard running mode of air compressor system Instrument air compressor supplies instrument air to plant, while service air compressor supplies miscellaneous air to plant. Interconnection valve of instrument air and miscellaneous air is closed.

（2）

Nonstandard running mode of air compressor system

When service air compressor is put out of use due to failure, instrument air compressor will supply instrument air and miscellaneous air to plant.

If pressure of instrument air system can not be maintained because an instrument air compressor is being inspected or maintained, it is permitted to supply air by interconnecting miscellaneous air and instrument air.

9.

Safety Measures

9.1


9.1.1


9.1.2


9.1.3


9.1.4


9.2


9.2.1

Adequate fire-fighting apparatuses are accessible in operating field according to requirement and can be used.

9.2.2

Civil work is finished and the covers of installation holes and openings and trenches are installed.

9.2.3

There is no inflammable, explosive, toxinic and corrosive gas in surrounding environment.

9.2.4

Do not touch rotating parts such as coupling by hand, arm or other part of body or with clothes. Do not clean, wipe or lubricate rotating parts of running equipment. When wipe stationary parts of equipments, do not wrap cotton yarn or rag around hand.

9.2.5

Do not start compressor when guard of rotating part or other part is removed. Doors on unit should be closed unless it is repaired or maintained.

9.2.7

Make sure that there is no person in unit when start it. Steam vent should not be directed to any part of body.

9.2.8

Wear goggles or mask when add antifreezing oil.

9.2.8

When enter enclosure to adjust air compressor, it is important to cut off power supply and assign dedicatedly a person to supervise it, and inform other staffs, set up a sign outside the door, and jam the door to prevent others from closing the door.

9.2.9

When compressor is running, each vent shall be supervised by person specially assigned. No one should approach air vents.

9.3


9.3.1

Blowdown piping and oil drain piping shall be clear and can be put into operation.

9.3.2

Operators must read carefully and understand relevant instruction manual in advance.

9.3.3

It is strictly prohibited to change the configuration and control mode of equipment at will unless written authorization is issued by manufacturer.

9.3.4

Shut down equipment and unload it, then cut off power supply before maintain and adjust it.

9.3.5

Shut down the equipment and make sure that its internal piping is not pressurized before open the cover of oil filter.

9.3.6

It is not permitted to start equipment if cooling system or oil piping is in abnormal condition.

10.

Appendix

10.1


Items

Requirements

1

Installation of system

Installation over, record complete

□Yes □No

2

Trial run of single equipment

Qualified

□Yes □No

3

Measuring meters and gauges

Complete and calibrated

□Yes □No

4

Sign of equipment sign

Complete and correct

□Yes □No

5

Field condition

Passage clear, adequate lighting, emergency lighting available

□Yes □No

6

Communication device

Available

□Yes □No

7

Fire apparatus

Adequate and easily accessible

□Yes □No

8


Complete and adequate

□Yes □No

9

Tools for running, record sheet

Prepared

□Yes □No

10

Tools, instruments and apparatuses for commissioning

Prepared

□Yes □No

11

Electrical connection

Secure and reliable

□Yes □No

12

Oil separator

Oil level appropriate

□Yes □No

13


Clear and free of leakage

□Yes □No

14

Vent valve

Operated freely

□Yes □No

15

Gauges and meters

Complete and verified

□Yes □No

Commissioning Contractor: Contractor: Owner:

Date:

Date:



Verified by

Result

Date: Date:

Rem arks

10.2

Appendix 2

Instrument Air Compressor Valve Record Instrument Air Compressor Valve Record

KKS code

Name of damper

00QFA10AA0 01

COMMUNICATING PIPE MOTORIZED VALVE

00QEA20AA 001

SERVICE AIR COMPRESSOR OUTLET MOTORIZED VALVE


Remote Direction

Feedback


Off(Close)


Date:

Operation Contractor ：

Date:

Contractor:

Date:

Dongfang Electric:

Date:

Owner:

Date:

Date

Result

Signat ure

Remark s



PT.PLN(PERSERRO)

Owner’s DWG No.


0702-00-M-01-EG-001 PT.PLN(PERSERRO) JAVA MANAJEMEN KONSTRUKSI

CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY SiChuan Electric Power Commissioning & Test Institute Approval


Check Design

DETAIL DESIGN STAGE

Procedure of Fuel Oil System

Review Date

Scale

N/A

DWG No.


REV

A



REV A


Page 2 of 29


PURPOSE .................................................................................................................................... 3

2.

SCOPE ......................................................................................................................................... 3

3.


4.


5.

TOOLS AND INSTRUMENT FOR COMMISSIONING........................................................... 3

6.


7.


8.


9.

SAFETY MEASURES .............................................................................................................. 17

10.

9.1

Safety Rules for Commissioning........................................................................................ 17

9.2

Personal Risk and Preventative Measures.......................................................................... 17

9.3

Equipment Risk and Preventative Measures ...................................................................... 17 APPENDIX................................................................................................................................ 18

Appendix 1 Commissioning Condition Checklist.............................................................................. 19 Appendix 2 Parameter Record Format for System Operation............................................................ 21 Appendix 3 Test Record Format for Oil Gun Atomization Output .................................................... 22 Appendix 4 Inspection Record Format for Lighting-up Program Control......................................... 23 Appendix 5 Commissioning Record Format of Control Valves......................................................... 24 Appendix 6 Valve Inspection Record Format .................................................................................... 25 Appendix 7 Test on Oil Gun and Ignition Gun .................................................................................. 28


1.


REV A


Page 3 of 29

Purpose The fuel oil system is commissioned to make oil system operation normal before start the trial run of the unit to ensure that the unit put into service newly can operate safely and economically to achieve the purpose of low consumption of oil.

2.

Scope This Procedure is applicable for commissioning of sub-systems of oil system, including fuel oil system before boiler, oil feed main piping system and pump house system.

3.

Preparation Basis

3.1

Layout plan of fuel oil pipeline;

3.2

Instrument control system chart of fuel oil system;

3.3

Boiler operation manual；and

3.4

Manual of combustion equipment.

4.

Brief Description of System and Equipment The boiler fuel oil system of PLTU 1 Jatim-Pacitan (2×315MW) Project is divided, as per their functions to oil unloading, storage, oil supply, control before boiler and oil burner systems. There are exterior MPH and interior MPH fuel oil systems when divided as per areas, among which the exterior MPH is a common system for two boilers. The main function of the fuel oil system is to transfer the fuel oil unloaded by truck unloading system to the storage tank and the oil supply system is to transfer the diesel oil with certain pressure and flow via the fuel oil console before boiler to the four corner burners at each layer to ensure the stable firing in the furnace and provide the ignition energy for pulverized coal during the startup and shutdown process of the unit and operation at a low load and also during the process of coal mill startup and shutdown. The oil unloading pumps, oil feed pumps and oil coolers of the exterior system of MPH are arranged in the fuel oil pump house, the two oil storage tanks with capacity of 1500m3 are installed inside the fire wall outside of the oil pump house. The oil return governing is used in the interior oil system of MPH; four corner oil burning devices are equipped, together 12 oil guns with the total input quantity of heat of 25%B-MCR of the boiler load. In addition the system also includes auxiliary systems, such as the fuel oil auxiliary steam system and the compressed air system which provides power for pneumatic equipments. 13 layer nozzles are arranged for each corner burner, including 5 layer of primary air nozzles, 1 layer top of secondary air (OFA)nozzles, 7 layer of secondary air nozzles (among them fuel oil devices are arranged in 3 layers). The offset perimeter air is arranged around the primary air nozzles. The fuel oil equipment is consisted of the oil guns and their thrusters, 12 sets for each boiler, which are arranged in the secondary air (oil) nozzles in three layers.

5.


5.1

Walkie talkie；

5.2




REV A


Page 4 of 29

5.3

Infrared thermometer.

6.


6.1


6.1.1

Within the range of system, the ground shall be level; the access free, covers of trench complete and the environment shall be clean and without sundries.

6.1.2

The platforms, ladders, railings and guard sheets within the range of the system shall be complete and the scaffoldings have been removed completely.

6.1.3

There shall be enough permanent illumination and temporary illumination shall be provided, if necessary.

6.1.4

There is reliable communication equipment at the site.

6.1.5

There are enough fire fighting apparatuses available at the site.

6.1.6

”Fire Forbidden” warning plates shall be placed at the places around the site.

6.2


6.2.1

The installation of the equipments, pipeline and auxiliary systems of the fuel oil system is completed.

6.2.2

The hydro test for fuel oil system is qualified.

6.2.3

The steam purging for the fuel oil system is completed.

6.2.4

The installation and commissioning of all corner burners are completed.

6.2.5

The trial run of a single oil pump is qualified.

6.2.6

Equipments and valves are already tagged and matched to the system.

6.2.7

The insulation for auxiliary steam system is completed and the paint mark is clear.

6.2.8

The oil discharge valve and empty valve inside the fuel oil system is fulfilled and closed, and the isolated valve of DG is ensured to be closed tight and locked dead.

6.3


6.3.1

The single commissioning of the oil gun ignition control cabinet is completed, the electronic ignition gun and oil gun move back and forward freely and to the position without unsmooth. The correct position of the ignition gun and oil gun is confirmed.

6.3.2

The measurement points and measurement elements in site the fuel oil system have been successfully installed and commissioned after the calibration is satisfactory and ready for operation.

6.3.3

The commissioning of oil pumps in the fuel oil system is completed and a proper operation is confirmed, the parameter is normal and CRT status indication is correct.

6.3.4

The commissioning of separate valve is completed, the open and close action is normal, the local position and CRT status indication of limit switch is correct.

6.3.5

The test for interlock protection in the system is completed.

6.4

Other preconditions required to be available



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6.4.1

The parties of the contractor, builder owner, production and commissioning had been organized to conduct the large joint inspection, the problem, if found any, is rectified.

6.4.2

The preparation for production trial run has been completed and enough numbers of operators have been deployed and trained and passed the examination. The operation regulations and system chart have been approved, operation tools are available and the operation log is ready.

6.4.3

The enough and qualified fuel oil shall be ready.

6.4.4

Necessary maintenance tools and material shall be available.

6.4.5

The commanding organization of the trial run is established and work division is clear.

6.4.6

The commissioning materials, tools, instruments, meters and record formats are ready and complete.

6.4.7

The commissioning personnel concerning I&C, electrical and mechanical of the installation company are available at site.

6.4.8

The clarification of measures is completed.

7.


7.1

Responsibilities of Commissioning Contractor ◆ Preparation and revision of commissioning procedures; ◆ Preparation of commissioning plan; ◆ Preparation of instruments and equipment required for commissioning； ◆ Hold technical disclosure meeting for commissioning; ◆ Organize the commissioning work to be carried out by various parties; ◆ Give instructions to operators in the operation; ◆ Prepare commissioning report.

7.2

Responsibilities of Installation Contractor ◆ Be responsible for individual commissioning of equipment and provide relevant record and certificate of commissioning; ◆ Be responsible for inspection, maintenance and defect elimination of equipment under commissioning； ◆ Prepare maintenance tools and materials necessary for commissioning； ◆ Assist the commissioning contractor in the commissioning of subsystems； ◆ Be responsible for temporary coordination of local I&C components and connection terminals.

7.3

Responsibilities of Equipment Manufacturers ◆ Representative of manufacturer, if present on the site offering service, shall provide technical assistance during equipment commissioning.

7.4

Responsibilities of Plant Operator



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◆ Prepare tools to be involved in operation; ◆ Prepare operation log and forms; ◆ Operate the system and equipment according to the operating procedures and the instructions of the commissioning personnel; ◆ Be responsible for patrol inspection, check, and normal maintenance of system and equipment; ◆ Be responsible for dealing with the accidents occurred in commissioning。 7.5

Responsibilities of Dongfang Electric ◆ Be responsible for supervision and control over commissioning work; ◆ Coordinate with commissioning contractor, the Owner, and other contractors in the commissioning. ◆ Participate in and witness the commissioning work; ◆ Organize analysis and settlement of major technical issues in commissioning。

7.6

Responsibilities of Owner ◆ Supervise the execution of commissioning procedures; ◆ Witness the commissioning work; ◆ Accept the results of commissioning。

8.


8.1

Cold check and transmission test of valve

8.1.1

Check and accept motorized and pneumatic open/close valves and record the following data: Check if KKS code, designation and local position indication is correct, if the remote operation direction and feedback is satisfactory, valve open (close) time, test date and signature by person in charge of test. Refer to Appendix 6 for details.

8.1.2

Check the motorized or pneumatic regulating valves and enter the following data on the records: KKS code, designation, local position indications and feedback indications corresponding to upward command of 0%, 50%, 75%, and 100% and downward command of 100%, 75%, 50% and 0% respectively, confirm if local position indication is correct, test date, signature by person in charge of test. Refer to Appendix 4 for other requirements.

8.1.3

Test and acceptance of oil gun and ignition and recording the following data Check if KKS code, designation and local position indication is correct, if the remote operation direction and feedback is satisfactory, open (close) time, test date and signature by person in charge of test. Refer to Appendix 7 for details.

8.2

Interlock protection and alarm test (Note: the result of logic discussion will prevail for the test items of the interlock protection) The test for interlock and alarming confirmation of the system will be carried out after completion of commissioning of SCS, DAS and FSSS of I&C.

8.2.1 Sr.N o.

Interlock test for fuel oil system before boiler Test item

Fixed value

Results

Remarks



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1.

Permissive condition for boiler fuel oil system ignition

(1)

Without MFT condition

(2)

Without OFT condition

(3)

Air flow in the furnace normal and total air flow>30%

(4)

Furnace pressure normal

(5)

Flame detector cooling air pressure normal >5KPa

(6)

Fuel oil inlet cut-off valve open and oil feed pressure normal

(7)

Oscillation burners in level position

(8)

Oil leakage test success or bypass

(9)

Fuel oil purging normal

(10)

Furnace purging finished

2.

Single oil gun lighting up permissive conditions

(1)

Oil system lighting up conditions satisfactory

(2)

Power for ignition cabinet normal

(3)

The ignition cabinet in program control mode

(4)

Without ignition failure

(5)

Purging valve in close position

(6)

Without OFT

3.

Single oil gun tripping conditions

(1)

Oil gun lost flame scanning

(2)

Failure in oil valve opening

(3)

Failure in oil gun entering

(4)

Ignition failed

(5)

Material tripping(MFT,OFT)

(6)

Shutdown by operators

4.

OFT action conditions

(1)

With MFT

(2)

The rapid close valve of fuel oil is closed when any oil corner valve not is closed,

(3)

Oil supply piping main pressure LL<2.4Mpa (2 of 3 logic) when any oil corner valve is not closed and the oil rapid close valve is not closed.

5．

Result of OFT action

(1)

OFT action alarming

(2)

Fuel oil input rapid close valve closed


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(3)

Fuel oil return motorized valve closed

(4)

All the oil angle valve closed

(5)

All the purging valves closed

(6)

fire striking of all ignition guns ended and back to position

(7)

All the oil guns back to position

6． (1) 7． (1)

(2)

(3)

8.

Reset of OFT conditions Without OFT action conditions Rapid close off valve of oil feed header Permissive condition for open (the following conditions shall be met at the same time) No existence of OFT/MFT conditions All oil corner valves closed Oil feed pressure normal Conditions for open interlock: (the valve opening by interlock under any conditions as below) Oil leakage test to open oil feed rapid close valve Conditions for close of interlock: (the valve closing by interlock under any conditions as below) MFT/OFT action existence Oil feed pressure abnormal Oil leakage test to close oil feed rapid close valve Failure of boiler oil leakage test Boiler oil return motorized valve

(1)

Permissive conditions for open All the oil corner valves closed

(2)

Conditions for open of interlock: (the valve opening by interlock under any conditions as below) Oil leakage test to open oil return motorized valve by interlock

(3)

Conditions for close of interlock: (the valve closing by interlock under any conditions as below) OFT interlock permissive true, MFT/OFT action existence Oil leakage test to open oil return motorized valve Failure of boiler oil leakage test

8.2.3 Sr.No. 1.


Interlock Protection Test for Fuel Oil Pump House System Test item Startup conditions for oil unloading pump A

Fixed value

Results

Remarks


(1) 2.


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Remote position Tripping conditions for oil unloading pump A

(1)

Oil unloading pump A in operation, outlet pressure LL

(2)

Oil unloading pump A in operation, failure

3. (1) 4.

Startup conditions for oil unloading pump B Remote position Tripping conditions for oil unloading pump B

(1)

Oil unloading pump B in operation, outlet pressure LL

(2)

Oil unloading pump B in operation, failure

5.

Interlock protection for oil unloading pumps

(1)

Oil unloading pump A in operation, interlock of oil unloading pump B in service

(2)

Interlock shutdown both pumps when outlet pressure is low when oil unloading pump A is in operation and the outlet header pressure of the oil unloading pump B started by interlock is still low.

(3)

Interlock opens the standby oil unloading pump B when the oil unloading pump A in operation is failure and tripped.

(4)

Oil unloading pump B in operation and oil unloading pump A in service of interlock

(5)

Interlock shutdown both pumps when outlet pressure is low when oil unloading pump B is in operation and the outlet header pressure of the oil unloading pump A started by interlock is still low.

(6)

Interlock opens the standby oil unloading pump A when the oil unloading pump B in operation is failure and tripped.

6. (1) 7. (1) 8. (1) 9. (1) 10. (1) 11. (1)

Startup conditions for oil feed pumps Remote position Tripping conditions for oil feed pump A Operation failure of oil feed pump A Startup conditions for oil feed pump B Remote position Tripping conditions for oil feed pump B Operation failure of oil feed pump B Startup conditions for oil feed pump C Remote position Tripping conditions for oil feed pump C Operation failure of oil feed pump C


12


Page 10 of 29

Oil feed pump A in operation, B and C in standby and B in service by interlock

1)

When oil feed pump A is in operation and outlet oil pressure is Low, the standby oil feed pump B is started up by interlock

2)

When oil feed pump A is in operation and oil feed pump A is failure and tripped, the standby oil feed pump B is started up by interlock Oil feed pump B in operation, C and A in standby and C in service by interlock

(2)

3)

When oil feed pump B is in operation and outlet oil pressure is Low, the standby oil feed pump C is started up by interlock

4)

When oil feed pump B is in operation and oil feed pump B is failure and tripped, the standby oil feed pump C is started up by interlock

(3)

1

REV A

Test for interlock protection in oil feed pumps

(1)

13.


Oil feed pump C in operation, A and B in standby and A in service by interlock

1)

When oil feed pump C is in operation and outlet oil pressure is Low, the standby oil feed pump A is started up by interlock

2)

When oil feed pump C is in operation and oil feed pump C is failure and tripped, the standby oil feed pump A is started up by interlock I&C protection alarming of fuel oil system If outlet press. of fuel oil feed pump is low（<2.8Mpa） , give an alarm

2 If outlet press. of fuel oil feed pump is low-low （<2.5Mpa）, give an alarm 3

If outlet press. of fuel oil feed pump is high （>3.3Mpa）, give an alarm

4

If outlet press. of fuel oil feed pump is high-high （>3.5Mpa）, give an alarm

5

If outlet press. of fuel oil feed pump is high-high-high （>3.8Mpa）, give an alarm

6

If fuel oil press. is low（<2.5Mpa）, give an alarm

7

If fuel oil press. is low-low（<2.0Mpa）give an alarm

8

If fuel oil press. is high（>3.1Mpa）, give an alarm

9

If fuel oil press. is high-high（>3.3Mpa）. give an alarm



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10

If fuel oil press. is high-high-high.（>3.5Mpa）, give an alarm

11

Electrical failure and tripped of oil feed pump and the pump will trip and alarm

14.

Motorized control valve of outlet recirculation of oil feed pumps

1

Single loop control to control the oil feed pressure

8.3

Trial run and oil circulation of oil pumps

8.3.1

The motor trial run has been satisfactory and the interlock protection completed prior to the trial run of the oil pump.

8.3.2

Check for normal oil level in oil tank and the oil unloading pump shall be supplied with enough oil.

8.3.3

Before trial run of oil pumps, cooling water and seal liquid shall be in service, the oil pumps and inlet pipeline system shall be charged and charge the oil pumps with oil after the air in the pipeline is emptied.

8.3.4

Startup the oil pump after the pump is charged with oil, close the outlet valve and check for correct loop of the system. When the pump is started for the first time, shutdown the oil pump when the pump is started and reached the rated rotating speed and check for vibration, rotating direction and mechanical friction and start the pump again when all the same are normal. Check the vibration setting which shall not exceed the stipulated value and the leakage in shaft gland shall be a little and even during operation.

8.3.5

start the small circulation of the pump house oil system.

8.3.6

In the process of oil circulation in service, monitor that the all parameters of the system shall be in normal range, including I/O oil pressure, oil temperature, pressure difference in the strainer, bearing temperature of pumps, current and vibration.

8.3.7

After the oil circulation is established and running normally, the recirculation valve can be closed down to control the oil pressure to charge pressure to the oil feed main pipeline, feed oil to boiler house and put the large circulation in to service.

8.3.8

All the pipelines of the oil system shall be checked for oil leakage and flow out after the oil system pipeline is charged with pressure.

8.4

Check for solenoid valve leakage All the solenoid valves are closed, the manual valve is open and the pressure of header before boiler is 3.0Mpa, confirm, locally, that there is no leakage in the solenoid valves. The test report shall be kept properly. Result (local confirmation)

Sr.No. Tight not leakage AB1 solenoid valve AB2 solenoid valve AB3 solenoid valve AB4 solenoid valve BC1 solenoid valve

Slight leakage

Serious leakage



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BC2 solenoid valve BC3 solenoid valve BC4 solenoid valve DE1 solenoid valve DE2 solenoid valve DE3 solenoid valve DE4 solenoid valve 8.5

Output and atomization test for oil guns

8.5.1

Output test for oil guns The oil gun output and atomization tests can be carried out after the oil circulation in the oil system is established and the location of the test can be located near the place where the oil guns are installed. Adjust the oil pressure before the oil gun to the pressure required by the test and open the inlet valve of the oil gun to make the oil injecting into the oil barrel. After timing for a period, close the inlet valve of the oil gun, weigh the additional weight of the barrel and calculate the oil gun output in a unit time. Measure the oil gun output under various oil pressure conditions with the same method above. Keep proper record of the test. See the appendix 3.

8.5.2

Atomization test for oil gun The atomization test can be carried out after the oil gun output test is completed. Adjust the oil pressure before the oil gun and open the inlet valve of the oil gun to make the oil injecting into the oil barrel and check the atomization and angle of injection visually and taking pictures. (3)Various oil pressure conditions can be selected to carry out the atomization test to determine the best parameter of the atomization. (4)The atomization test can be tested in no wind weather and the fire protection shall be done properly. Keep proper record of the test. See the appendix 3.

8.6

Status inspection and adjustment test for system When the fuel oil systems are operating, system equipment operation shall be monitored carefully. In case any deviation from normal operating status is found, timely adjustment shall be made to ensure that the systems are at optimum operating state. (1)

Test the switch motion of all the control valves, rapid cut-off valves and the solenoid values for correction motion and tight seal.

(2)

For the governing test of control valves, check the setting and governing of the oil pressure of fuel oil system.

(3)

Check for the steam pressure setting of fuel oil system purging.

(4)

Fuel oil leakage test and adjustment of oil charging pressure setting.


8.7


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(5)

Check for the position of the oil guns and ignition guns.

(6)

Switch time adjustment for combined valve of oil gun control.

(7)

Adjustment of oil gun ignition time and flame scanning time.

Fuel oil leakage test Coordinate with I&C to complete the leakage test prior to ignition: Test item

Sr.No.

Permissive conditions for oil leakage test startup (1)

Request of oil leakage test

(2)

Furnace purging completed (No MFT conditions)

(3)

All the oil corner valves closed

(4)

Oil feed tripping valve closed

(5)

Oil back solenoid valve closed

(6)

Oil pressure in oil feed header normal

Startup of oil leakage test (1)

Permissive for oil leakage test startup

(2)

Bypass for non-oil leakage test

(3)

PB control

Program control procedures for oil leakage test (1)

Program control startup

(2)

Carry out the oil leakage test

(3)

First step: first, open the rapid close valve of oil header and oil return solenoid valve to do the oil circulation

(4)

Second step: close the oil return motorized valve after a period (60s) of oil circulation to charge all the pipelines and valves of the oil system with pressure to the pressure of oil header（X0HJF50CP201）3.2MPa greater than the normal work pressure after closing the oil header rapid close valve. Close the oil header rapid close valve.

(5)

Third step: remember the simulated pressure X value after close the oil header rapid close valve. At this moment, observe the pressure changes which shall be kept within the stipulated permissible range after the oil header rapid close valve is closed. Record pressure Y value after delay for 90s. If X-Y greater than 0.36MPa, the oil leakage test is not qualified and it is qualified when it is less than 0.36MPa.

Results


(6)


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Fourth step: the test for oil header rapid close valve can only be carried out until there is no leakage in the third step is confirmed. Open the oil return motorized valve to discharge the pressure to the low pressure switch（X0HJF50CP301） action after closing the oil header rapid close valve and then close the oil return motorized valve and record the pressure Y value. Observe the outlet pressure changes of the oil header rapid close valve. Record Y value within 180s and when Y-X is greater than 0.36MPa, the leakage test is not passed. When it is less than 0.36MPa, the test is passed and the whole test is successful.

The oil leakage test is failed if any of the abnormal conditions is met for alarm in the process of the oil leakage test. (1)

Failure in oil feed tripping valve

(2)

Failure in oil return tripping valve

(3)

Oil charge pressure low

(4)

Oil charge press HH

(5)

Failure in oil charge seal

(6)

Oil discharge seal failure

Oil leakage test successful

8.8

(1)

Bypass of oil leakage test (Note: all the oil corner valves must be closed completely.

(2)

The oil leakage test completed

Sequence control startup procedure for oil guns All the oil guns shall complete the startup procedure Sr.No.

8.9

Test item

(1)

First step：oil gun pushing in

(2)

Second step：Oil gun purging

(3)

Third step：igniter pushing in

(4)

Fourth step：fire striking (30S back)

(5)

Fifth step： Open corner valve, fire at flame scanning and oil gun in service

Fixed value

Results

Remarks

Fixed value

Results

Remarks

Sequence control end procedure for oil guns All the oil guns shall complete the shutdown procedure No.

Test item


8.10


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(1)

First step： igniter pushing in

(2)

Second step： fire striking (30S back)

(3)

Third step： close oil inlet valve

(4)

Fourth step： Open purging valve to purge the oil guns

(5)

Fifth step： close purging valve

(6)

Sixth stop：Withdraw oil gun

Program control actuation test for oil guns Oil gun program control of startup and shutdown test will be recorded in the format below: Remote program control of single corner Sr.No. Startup

Shutdown

Purging

AB-1 AB-2 AB-3 AB-4 BC-1 BC-2 BC-3 BC-4 DE-1 DE-2 DE-3 DE-4 Remote program control of across corner No. Startup AB1/3

Shutdown



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AB2/4 BC1/3 BC2/4 DE1/3 DE2/4 Remote program control of layer No. Startup

Shutdown

AB BC DE 8.11

First lighting up and shutdown of oil guns The ignition conditions availability is confirmed and approval by the trial run commander in chief is obtained. Use the light diesel oil to light up as per DCS procedures.

(1)

Start the flame scanning cooling fans and the standby fans are put into service of interlock.

(2)

Shutdown the bottom heating system and the water level in the steam drum is at about -100mm.

(3)

Start the two air preheaters and put them in service of interlock.

(4)

Start ID fans and FD fans.

(5)

Building up air flow for purging, purge the furnace for 5s and return to MFT.

(6)

Carried out the fuel oil system leakage test.

(7)

Adjust the total air flow and opening of the secondary air damper after returning of MFT and the secondary air pressure difference shall be 250～450Pa and the negative pressure in the furnace about -50Pa.

(8)

Check the opening of all baffles in the air duct and flue duct which shall be in the correct position.

(9)

Confirm all of the boiler protection is in service . If the protection conditions are not mate, I&C can be temporarily cut off with the approval of the commander in chief and record of the same shall be properly kept. Protection of I&C shall be put into service immediately when the protection service conditions are met.

(10)

Build and maintain the fuel oil pressure at 3.1—3.3 MPa before boiler. Light up and put 1 to 2 oil guns in to service as per conditions. Pay attention to check the firing and atomization after ignition. The operation of oil guns shall be adjusted timely to ensure proper atomization, clear flame without black smoke. Select the oil guns at the lowest layer and put them in service by across corner at the initial stage of ignition and switch over once in 30m (for instance, 1 and 3 corners to 2 and 4 corners) to ensure that the water cooling wall to be heated evenly. The air distribution shall be check at the time when oil is filled and the adjustment shall be done properly in time to it burn completely. For the oil gun which is not burning properly, it shall



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be removed, checked and cleaned in time. The fuel oil shall be cut off immediately when ignition is failed or the oil gun is extinguished. The re-ignition cannot be carried out until completion of oil gun is purged and furnace ventilated and purged. (11)

Inform I &C to carry out oil flame scanning. The flame scanning shall be put into service immediately after each of the oil flame scanner is adjusted normal.

(12)

Put the outlet flue gas temperature probes after the fire is normal. When there is no steam passing through RH and during steam blowing, the outlet flue gas temperature of the furnace shall be controlled not more than 538℃. If the flue gas temperature exceeds 538℃, the quantity of fuel in service shall be immediately reduced to ensure that the RH operates safely.

(13)

Continue to trial putting other oil guns in service and adjust the firing and commission the flame scanning. Shutdown the standby equipments when the oil burners are in normal service.

8.12

System operation at the period of integral startup Test the operation reliability of the system as per stages of non-load, with load, full load and 30d reliable operation. (1)

Dynamic regulation of system: in the process of system being brought into service and when the special fuel oil pressure adjustment is required, the monitor of the equipments shall be enhanced to ensure that the system is in the best operation state.

(2)

Complete trial operation record: for main parameters in the startup trial run, refer to Appendix 2.

9.

Safety Measures

9.1


9.1.1


9.1.2


9.1.3


9.2


9.2.1

The ground around oil system before boiler shall be level and no barriers and the material which is not required shall be removed completely.

9.2.2

“Fire Forbidden” warning plate shall be placed within 10m from the oil pipeline when the commissioning of oil system before boiler is conducted.

9.2.3

Fire and welding of boiler proper is forbidden when the test of oil gun atomization is conducted.

9.2.4

The fire fighting apparatuses for oil system before boiler are ready and conforming to the requirement of fire fighting

9.3


9.3.1

The fuel oil temperature shall be monitored and the highest temperature shall not exceed 45℃.

9.3.2

Reliable isolation to other non-running system shall be ensured during operation of fuel oil



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system 9.3.3

If there is any leakage from the place where the pipeline and the oil gun and oil system before boiler is connected flexibly, it shall be rectified timely.

9.3.4

When the oil gun is out off operation, the inside of it shall be purged clean and the gun shall be back to position.

9.3.5

After the fuel oil system is charged with oil, if firing is required in maintenance, the firing card shall be got and the approval from the commander in chief shall also be available.

9.3.6

After the oil gun is in service, the firing adjustment shall be enhanced to ensure proper firing. Ash blowing for APH shall also strengthen.

9.3.7

Any things not described herein shall strictly follow the treatment of “Boiler Operation and Accident Regulations”.

10.

Appendix



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Appendix 1 Commissioning Condition Checklist Sr.No.

Items

1.


Requirements

Result

(1)



□Yes □No

(2)


Complete Removed

□Yes □No

(3)

Illuminating

Sufficient

□Yes □No

(4)


Reliable

□Yes □No

(5)

Fire apparatus


□Yes □No

(6)

Warning plate

Location correct and eye striking

□Yes □No

2.

Mechanical conditions

(1)

Installation

All fulfilled

□Yes □No

(2)

Hydraulic pressure test

Qualified

□Yes □No

(3)

Steam purging

Fulfilled

□Yes □No

(4)

Oil burners

Installation completed

□Yes □No

(5)

Single oil pump

Trial run qualified

□Yes □No

(6)

Equipment and valves

Plate and correct

□Yes □No

(7)

Auxiliary steam system

Insulation complete and marking clear

□Yes □No

(8)

Isolation

Fulfilled

□Yes □No

Single commissioning completed

□Yes □No

Calibration qualified and indication correct

□Yes □No

3.

nomination

Conditions for electrical and I&C

(1)

Ignition control cabinet

(2)

Measure points measure element

(3)

Oil pump control

Operation good and status indication correct

□Yes □No

(4)

Single valve

Commissioning completed, actuation normal and status indication correct

□Yes □No

(5)

Interlock protection and alarming

Test eligible

□Yes □No

4.

Other conditions

and

Verified by

Remarks



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(1)

System inspection

Completed, error correction completed

□Yes □No

(2)


Operators deployed, operation tools ready and operation log ready

□Yes □No

(3)

Fuel oil

Storage adequate and quality of oil conforming to design

□Yes □No

(4)

Overhaul materials

Complete

□Yes □No

(5)

Commanding organization system

Established and division clear

(6)

Commissioning materials, tools, instruments, meters and record formats

Ready and complete

□Yes □No

(7)



□Yes □No

(8)

Clarification for methods

Fulfilled

□Yes □No

Date:


tools


Date:

and

work

Dongfang Electric:

□Yes □No

Date:

Date:



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Appendix 2 Parameter Record Format for System Operation Time Name Unit load

Work conditions Unit

Data

Name

Unit

MW

Outlet press. of oil feed pump A

PA

Fuel oil inlet flow before boiler

T/h

Outlet press. of oil feed pump B

%

fuel oil outlet flow before boiler

T/h

Outlet press. of oil feed pump C

%

Fuel oil press. Before boiler

MPa

Fuel oil temp. before boiler

℃

Purging steam press. Before boiler

MPa

Purging steam temp. Before boiler

℃

Oil gun input

Pcs.


Date:

Oil level in oil tank A

mm

Oil level in oil tank B

Date:

mm

A oil tank temp.

℃

B oil tank temp.

℃


Dongfang Electric:

Data

Date:

Date:



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Appendix 3 Test Record Format for Oil Gun Atomization Output Atomization piece specification (t/h)

Atomization inspection FO press. （3.0-3.5MPa)

Output determination

Atomization angle

Atomization effect

Local output(t/h)

DCS counted output (t/h)

AB1 AB2 AB3 AB4 BC1 BC2 BC3 BC4 DE1 DE2 DE3 DE4


Date:

Date:


Dongfang Electric:

Date:

Date:



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Appendix 4 Inspection Record Format for Lighting-up Program Control Sr.No.

Single corner remote program control Startup

Shutdown

Purging

AB-1 AB-2 AB-3 AB-4 BC-1 BC-2 BC-3 BC-4 DE-1 DE-2 DE-3 DE-4 No.

Across corner remote program control Startup

Shutdown

AB1/3 AB2/4 BC1/3 BC2/4 DE1/3 DE2/4 No.

Layer remote program control Startup

Shutdown

AB BC DE


Date:

Date:


Dongfang Electric:

Date:

Date:



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Appendix 5Commissioning Record Format of Control Valves Commissioning Record Format of Control Valves KKS code 00EGC41 AA101

X0HJF60 AA101

0%

25%

50%

75%

100%

75%

50%

FUEL OIL RECIRCULATING CONTROL VALVE IN PUMP HOUSE VALVE FUEL OIL RECIRCULATING CONTROL VALVE BEFORE BOILER


Feedback of ascending and descending instruction values

Items

Date:

Date:


Dongfang Electric:

Date:

Date:

25%

0%

Date

Result

Signature

Remarks



REV A


Page 25 of 29

Appendix 6Valve Inspection Record Format Valve Commissioning Record Format Remote Local indicated position

KKS code

Items

X0HJF50AA002

SUPPLYING OIL SHUT-OFF VALVE

X0HJF60AA003

RETURN FUEL MOTORIZED VALVE

OIL

1AB FUEL OIL SOLENOID VALVE 1AB PURGE VALVE

SOLENOID


SOLENOID


SOLENOID

4AB FUEL OIL SOLENOID VALVE

Directio n correct

Operating time Feedbac k correct

On (Open)

Off (Close)

Date

Result

Signature

Remarks



REV A


Page 26 of 29

4AB PURGE VALVE

SOLENOID

1BC FUEL OIL SOLENOID VALVE 1BC PURGE VALVE

SOLENOID


SOLENOID


SOLENOID


SOLENOID

1DE FUEL OIL SOLENOID VALVE 1DE PURGE VALVE

SOLENOID


SOLENOID



REV A


Page 27 of 29


SOLENOID

4DE FUEL OIL SOLENOID VALVE 4DE PURGE VALVE Commissioning Contractor: Contractor:

Date:

SOLENOID

Date:


Dongfang Electric:

Date:

Date:

PLTU 1 Jatim-Pacitan（2×315MW） Project Commissioning Procedure Appendix 7


REV A


Page 28 of 29

Test on Oil Gun and Ignition Gun Commissioning Record Format Remote

KKS code

Name

1AB oil gun 1AB ignition gun 2AB oil gun 2AB ignition gun 3AB oil gun 3AB ignition gun 4AB oil gun 4AB ignition gun 1BC oil gun 1BC ignition gun 2BC oil gun 2BC ignition gun 3BC oil gun 3BC ignition gun 4BC oil gun 4BC ignition gun 1DE oil gun

Local indicated position

Directio n correct

Operating time Feedbac k correct

On (Open)

Off (Close)

Date

Result

Signature

Remarks



REV A


Page 29 of 29

1DE ignition gun 2DE oil gun 2DE ignition gun 3DE oil gun 3DE ignition gun 4DE oil gun 4DE ignition gun Commissioning Contractor: Contractor:

Date:

Date:


Dongfang Electric:

Date:

Date:

Boiler Commissioning Procedure

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