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Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HL-002
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)
DESIGN STAGE
Test Institute Project
Approval Check
Procedure of Air Preheater System
Review Design
Date Scale N/A DWG No. SCCTI-TS-GL-CS-012-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Table of Contents
1. PURPOSE ..............................................................................................................................................................3
2. SCOPE ...................................................................................................................................................................3
3. PREPARATION BASIS.........................................................................................................................................3
Appendix 2 Parameter Record for Trial Run of APH and Its System........................................ 17
1. 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.
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
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;
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:
(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.
8.2.2 Check for alarm signal of APH A (B)
Remark
No. Test item Fixed value Results
s
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
8.2.6 Startup condition for interlock of main and auxiliary motors of APH
PLTU 1 Jatim-Pacitan(2×315MW) Project
8.2.7 Interlock test of outlet primary and secondary dampers and inlet flue gas baffle of APH
(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.
8.3.2 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.
8.3.3 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.
8.3.4 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Appendix 2 Parameter Record for Trial Run of APH and Its System
Parameter Record Format for Trial Run of APH and Its System
25.
01b OF APH A
X0HNA20AA0 FLUE GAS INLET DAMPER 1
01a OF APH B
X0HNA20AA0 FLUE GAS INLET DAMPER 2
01b OF APH B
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-EB-001
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
Table of Contents
1. PURPOSE 3
2. SCOPE 3
3. PREPARATION BASIS 3
8. COMMISSIONING PROCEDURE 9
9. SAFETY MEASURES 27
10. APPENDIX 27
Appendix 5 Check List for Programmed Control Startup and Shutdown and Interlock
1. 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 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.
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
Rem
No. Description Model & codec Unit Q'ty
arks
1 Speed monitor JSBHDJ-II model Set 10
2 two-step off tracking switch KPP-12-30 model Set 21
two-direction string-pulling
3 KLS-III model Set 50
switch
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
close preventative vibration JZF-6 model trigger vibration
7 Set 10
unit power 250kg and power of 0.4kW
8 coal blocking detector LDB-X model Set 10
9 metal detector Applicable belt width1200mm Set 2
◆ 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;
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning;
8. Commissioning Procedure
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
operation
Tripping alarm condition for C-1A 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-2Abelt conveyor operation
shutdown
C-2A belt conveyor startup condition
(1) At remote location
(2) No belt conveyor integrated failure signal
(3) flow selection C-3belt conveyor in operation
Tripping alarm condition for C-2Abelt 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-3belt conveyor after operation,
operation shutdown
C-3belt conveyor startup condition
(1) At remote location
(2) No belt conveyor integrated failure signal
(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) 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 11 of 40
(2) Check for interlock shutdown condition of accessory equipment of belt conveyor
(4) ring hammer coal crusher A(B) startup tripping condition check
conveyor in operation
ring hammer coal crusher A tripping alarm condition
(1) electrical protection action
(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) Action of emergency button
(7) C-5Abelt conveyor in operation and C-4Abelt
conveyor shutdown
ring hammer coal crusher B startup condition
(1) At remote location
(2) No integrated failure signal
(3) C-5Bbelt conveyor in operation and C-4Bbelt
conveyor in operation
ring hammer coal crusher B tripping alarm condition
(1) electrical protection action
(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) Action of emergency button
(7) C-5Bbelt conveyor in operation and C-4Bbelt
conveyor shutdown
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.
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.
8.2.6.4 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
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 24 of 40
8.3.1.5 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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 25 of 40
The test for system interlock will be carried out as per five operation modes below and all
equipments will startup as per sequence.
◆ 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.
(2) 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.
8.4 System Operation during Integral Startup
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 27 of 40
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 Safety Rules for Commissioning
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 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.
9.1.4 All professional shall be on respective duties during the whole commissioning to guarantee
the safe operation of equipments.
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.
9.2.2 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 Equipment Risk and Preventative Measures
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 28 of 40
11 Hydraulic oil system Oil quality qualified and oil pump □Yes □No
operation normal
Appendix 5 Check List for Programmed Control Startup and Shutdown and Interlock for Equipment Flow of CHP
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)
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)
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 )
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 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)
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 )
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 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)
04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )
PLTU 1 Jatim-Pacitan(2×315MW) Project
05 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 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)
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 )
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 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)
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)
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
separator) →electric three-way pass B side→C-6Bbelt 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)
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)
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 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)
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 )
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 Program control startup (the downstream equipment starts up first and continue to the
last equipment)
PLTU 1 Jatim-Pacitan(2×315MW) Project
02 Program control shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)
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 )
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 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)
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 )
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 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)
PLTU 1 Jatim-Pacitan(2×315MW) Project
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 )
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 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)
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 )
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 Program control startup (the downstream equipment starts up first and continue to the
last equipment)
02 Program control shutdown (The upstream equipment shutdown first and continue to
the last equipment )
04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )
PLTU 1 Jatim-Pacitan(2×315MW) Project
05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
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 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)
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 )
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 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)
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 )
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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)
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 )
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HL-003
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Review Procedure of Primary Air Fan System
Design
Date DWG No. REV
Scale N/A SCCTI-TS-GL-CS-014-2009A A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 2 of 23
Table of Contents
1. PURPOSE ........................................................................................................................................... 3
2. SCOPE ................................................................................................................................................ 3
9. SAFETY MEASURES..................................................................................................................... 17
1. 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 Check the reliability of electric and I&C interlock protection and signal device.
1.3 To check equipment running, verify system performance, and detect and remove any potential
defects.
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
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 Conditions that must be available for electrical and I&C
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.
◆ 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;
8. Commissioning Procedure
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 7 of 23
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) Emergency button action
(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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 10 of 23
8.2.2.6 Interlock test for the cold air damper at outlet of PAF
1) Electrical failure
2) Emergency button action
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) 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.
9. Safety Measures
9.1 Safety Rules for Commissioning
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 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.
9.1.4 All professional shall be on respective duties during the whole commissioning to guarantee
the safe operation of equipments.
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 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 18 of 23
Verified Remar
No. Items Requirements Result
by ks
1. Environmental Conditions
(1) Site, road and environment Flat, clear and clean □Yes □No
(2) Platform, ladder, handrail, Complete
□Yes □No
guard plate and scaffold Removed
(3) Illuminating Sufficient □Yes □No
(4) Communication equipment Reliable □Yes □No
(5) Sufficient in quantity and
Fire apparatus □Yes □No
easy for use
2. Maintenance conditions
(1) Installation and heat
All fulfilled □Yes □No
insulation work
(2) Commissioning of fan
Qualified □Yes □No
monomer
(3) Thin oil station The debugging is qualified □Yes □No
(4) Commissioning is
Industrial cooling water completed and
□Yes □No
system commissioning can be
performed.
(5) Inner sundries Completing the clearing □Yes □No
(6) Equipment and valve Tagging, correct naming □Yes □No
(7) Manhole door Closed fully □Yes □No
Electrical and I&C
3.
condition
(1) The calibration is qualified
Measuring points and the
and the indication is □Yes □No
measuring gauge
correct
(2) The operation is favorable
Thin oil station and the display of status is □Yes □No
correct.
(3) After completing the
commissioning, the action
Single valve □Yes □No
is normal, the display of
status is correct.
(4) Interlock protection and
Test eligible □Yes □No
alarm
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 19 of 23
1 %
Moving blade opening, PAF A
3 KPa
Outlet air pressure, PAF A
5 mm/s
Bearing vibration, PAF A
11 ℃
Inlet air temperature, PAF A
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) 0702-00-M-01-QHD-001
DWG No.
PT.PLN(PERSERRO)
PT REKADAYA
JAVA MANAJEMEN
ELEKTRIKA
KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan
DESIGN
Commissioning & Test Institute (2×315MW) Project
STAGE
Approval
Check Procedure of Ash Removal and Deslagging
Review System
Design
Scale DWG No. SCCTI-TS-GL-CS REV
N/A A
Date -015-2009A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 2 of 30
Table of Contents
1. PURPOSE ........................................................................................................................................... 3
2. SCOPE ................................................................................................................................................ 3
9. SAFETY MEASURES..................................................................................................................... 23
1. 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 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 To check equipment running, verify system performance, and detect and remove any potential
defects.
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.
1 Dry-type slag One set for each boiler, model: GBL12A×25, capacity: 4-5 t/h
remover with slag pit, large sized slag squeezer, etc.
2 Single roller slag One set for each boiler, capacity: 5.50t/h,5.5KW; power of motor:
crusher 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 .
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 4 of 30
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
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
6 Air electric heater Six sets for two boilers. 45KW, 11.9m3/min 0.0784MPa
380V
7 Ash transmitter of field 1 Eight sets for two boilers. Capacity: 9.5T/H
8 Ash transmitter of field 2 Eight sets for two boilers. Capacity: 6.3T/H
9 Ash transmitter of field 3 Eight sets for two boilers. Capacity: 1.27T/H
10 Ash transmitter of field 4 Eight sets for two boilers. Capacity: 0.24T/H
Two sets for two boilers. Capacity: 100T/H,
11 Double shaft mixer P=22KW
Model: SZ200
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 6 of 30
13 Gasification Box of ash Sixty four sets for two boilers. 300X300
hopper
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 Two sets for two boilers. Model: 508
valve
17 Bulk loader Two sets for two boilers. Capacity: 100T/H
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.
◆ 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;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 9 of 30
8. Commissioning Procedure
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
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
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)
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 13 of 30
Electric field #1 transfer pipe clogged, program automatically goes to clogging removal cycle
period
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 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)
07 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
08 Close discharge valve
09 Re-enter the next cycle
In case transfer time exceeds 600s, give alarm, and the system will
10 automatically reset. Manual clogging removal shall be carried out
before carrying out programmed ash removal
03 Transfer pipe discharge, gulp valve and secondary air valve are in
close position
04 Feed sealing valve is closed
Flow of electric field #2 programmed control
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 14 of 30
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)
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
Electric field #2 transfer pipe is clogged. The program goes automatically to clogging removal
cycle period
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 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)
07 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
08 Close discharge valve
09 Re-enter the next cycle
In case transfer time exceeds 600s, give alarm, and the system will
10 automatically reset. Manual clogging removal shall be carried out
before carrying out programmed ash removal
03 Transfer pipe discharge, gulp valve and secondary air valve are in
close position
04 Feed sealing valve is closed
Flow of electric field #3 programmed control
01 Send programmed control start command
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)
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)
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 16 of 30
02 Close transfer air valve, gulp valve and secondary air valve
simultaneously and open ash pipe pressure relief valve
03 Transfer pressure is lower than 0.06MPa.
04 Close ash pipe pressure relief valve (delay by 3s)
05 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)
07 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
08 Close discharge valve
09 Re-enter the next cycle
In case transfer time exceeds 600s, give alarm, and the system will
10 automatically reset. Manual clogging removal shall be carried out
before carrying out programmed ash removal
03 Transfer pipe discharge, gulp valve and secondary air valve are in
close position
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 17 of 30
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)
10 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed 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)
14 Pressurize discharge sealing valve. Air pressure high is met
15 Re-enter the next cycle
Electric field #4 transfer pipe is clogged. The program goes automatically to clogging removal
cycle period
02 Close transfer air valve, gulp valve and secondary air valve
simultaneously and open ash pipe pressure relief valve
03 Transfer pressure is lower than 0.06MPa.
04 Close ash pipe pressure relief valve (delay by 3s)
05 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)
07 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
08 Close discharge valve
09 Re-enter the next cycle
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 18 of 30
In case transfer time exceeds 600s, give alarm, and the system will
10 automatically reset. Manual clogging removal shall be carried out
before carrying out programmed ash removal
03 Transfer pipe discharge, gulp valve and secondary air valve are in
close position
04 Feed sealing valve is closed
Flow of economizer fly ash settler programmed control
01 Send programmed control start command
05 Feed for 3s. any storage pump high level signal arrives or feed
time is delayed by another 10s.
06 Close the feeding of all the MD pump inlet dome valves of fly ash
settler (delayed by 5s)
02 Close transfer air valve, gulp valve and open ash pipe pressure
relief valve simultaneously
03 Transfer pressure is lower than 0.06MPa.
04 Close ash pipe pressure relief valve (delay by 3s)
(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.
8.6.3 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
(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.
8.7.2 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.
8.7.3 ESP no-load boosting test
Cooperate with the electrical specialty.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 23 of 30
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℃.
(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.
8.8 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 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.
9.1.4 All professional shall be on respective duties during the whole commissioning to guarantee
the safe operation of equipments.
9.2 Personal Risk and Preventative Measures
9.2.1 Rotating equipment
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 24 of 30
10. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 25 of 30
9 All safety valves of the system Completely equipped and □Yes □No
calibrated for satisfaction.
Commissioning finished
10 Programmed control system and have a correct logic □Yes □No
relationship.
Commissioning
11 Interlock and audio & visual finished and tested □Yes □No
alarm device
for satisfaction.
Clear road,
12 Field condition □Yes □No
sufficiency of illumination.
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-LB-001
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)
DESIGN STAGE
Test Institute Project
Approval Check
Procedure of Boiler Steam Blowing
Review Design
Date Scale N/A DWG No. SCCTI-TS-GL-CS-016-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 2 of 55
Table of Contents
1. 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 3 of 55
1. 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
766.0
Flow T/h 863.7 802.023 571.00 402.08
1
Inlet pressure MPa 3.99 3. 625 3.54 2.66 1.85
Outlet
Reheat MPa 3.80 3.438 3.38 2.53 1.76
pressure
steam
Inlet
℃ 329 322 320 313 318
temperature
Outlet
℃ 541 541 541 541 515
temperature
Temp. of feed water ℃ 281 275.5 273 255 234
(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
6.1.3 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;
6.1.4 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
6.1.5 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
6.1.6 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;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 6 of 55
(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) 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.
6.1.7 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.
6.1.8 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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 7 of 55
Outlet pressure for reheated steam Exhaust steam pressure for the temporary pipe
◆ Be responsible for the isolation work and the temporary listing work for relevant
systems and equipments
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 Operation Department
◆ Prepare tools to be involved in operation;
◆ 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 Corporation
◆ 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;
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.
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)
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)
Pressure of drum at the time of starting Pressure of drum at the time of closing
(MPa) (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
(4) Design pressure for the main exhaust pipe is P>1.5Mpa and t≥450℃。
10.17 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;
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:
Fixed Result
No. Test item Remarks
value s
1#and 2# recirculation motorized valves for boiler economizer
After 2# recirculating motorized valve is closed , 1#
(1) recirculation motorized valve is closed by means of
interlock
After 2# recirculating motorized valve is opened , 1#
(2)
recirculating motorized valve is by means of interlock
Boiler Steam pressure protection test
When the steam pressure of the steam header is
greater than 18.07Mpa, the ERV electromagnetic
(1)
pressure release valve is opened automatically to
relieve the pressure
When the steam pressure of the steam header is less
(2) than 17.6Mpa, the ERV electromagnetic pressure
release valve shall close automatically.
Boiler superheated steam header starting the1#and 2# exhaust motorized valve
After 2# exhaust motorized valve is closed , 1#
(1) exhaust motorized valve is closed by means of
interlock
After 2# exhaust motorized valve is opened , 1#
(2) exhaust motorized valve is opened by means of
interlock
Boiler reheated steam header starting 1# and 2# exhaust motorized valve,
After 2# exhaust motorized valve is closed , 1#
(1) exhaust motorized valve is closed by means of
interlock
interlock
Open/close conditions on the continuous blow down motorized valve and continuous blowdown
control valve
After opening the continue blowdown motorized
(1) valve, the manual control is allowed to open the
control valve
After closing the continuous blowdown control valve,
the interlock –close is performed or the manual
(2)
control is allowed to close the continuous blowdown
motorized valve
1# and 2# emergency drain motorized valves for boiler (setting the interlock operation switch)
The 1# and 2# emergency drain motorized valve shall
be closed by means of interlocking when the drum
(1)
level falls to below 100MM; high water-level alarm
should be performed.
The 1# and 2# emergency drain motorized valve shall
be opened by means of interlocking when the drum
(2)
level reaches 150MM; high water-level alarm should
be performed.
Interlock conditions for desuperheating water motorized valve and control valve
When MFT motion or load is less than 20%, the main
motorized valve and motorized sub-valve of
overheating system desuperheating water shall be
(1) closed by means of interlocking, and all
desuperheating water control valves shall be
automatically transformed into manual operation and
closed by means of interlocking.
When the first stage desuperheating water control
valve for superheater is closed (<5%) or MFT motion
(2) or load is less than 20%, interlock-close the
corresponding motorized sub-valve of the superheater
desuperheating water.
When the first stage desuperheating water control
valve of superheater is opened (>5%), interlock-open
(3)
the corresponding motorized sub-valve of the
superheater desuperheating water..
When the second stage desuperheating water control
valve at A side of the superheater is closed(<5%) or
(4) MFT motion or load is less than 20%, close the
corresponding motorized sub-valve of the superheater
desuperheating water by means of interlocking
When the second stage desuperheating water control
valve at A side of the superheater is opened(>5%),
(5) open the corresponding motorized sub-valve of the
superheater desuperheating water by means of
interlocking
When the second stage desuperheating water control
(6) 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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Procedure SCCTI-TS-GL-CS-016-2009A Page 18 of 55
11.2.5 Interlock protection test on flue-gas temperature probe and pneumatic oscillating device of
burner, including:
Fixed
No. Test item Results Remarks
value
(2) Repeat(automatic)
(2) Repeat(automatic)
Fixed
No. Test item Results Remarks
value
Fixed
No. Test item Results Remarks
value
Fixed
No. Test item Results Remarks
value
(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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 22 of 55
pressed.
(2) Draining pump B
1) Conditions for interlock initiation including the
followings:
Fixed
No. Test item Results Remarks
value
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Procedure SCCTI-TS-GL-CS-016-2009A Page 23 of 55
operation;
(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;
11.4 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;
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.
(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:
(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.
(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.
13.2 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.
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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.).
13.3 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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(9) 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.
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 35 of 55
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.
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.
15. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 37 of 55
Verified Rema
No. Items Requirements Result
by rks
1 Maintenance conditions
Completion of temporary pipe and heat
insulation (including drain, heat insulation, □Yes □No
etc.)
Completion for installation and
commissioning of temporary motorized □Yes □No
valve, bypass valve and drain valve.
Completion for manufacturing and
installation of target device and the quantity □Yes □No
is sufficient.
Temporary piping
Qualified for on/off test and light signal of
(1) system for □Yes □No
temporary motorized valve.
blowing
Completion for installation and acceptance
of temporary piping, fixing and sliding □Yes □No
hanger for counter-force framework
Completion of manufacturing and correct
□Yes □No
installation for the grain collector
Completion for installation and calibration
of the pressure gauge and the thermometer
□Yes □No
installed additionally for temporary system
for blowing.
Air pressure test is completed with
□Yes □No
acceptable quality
Completion for installation and heat
insulation of boiler proper and flue-gas and □Yes □No
Flue-gas and air air duct
(2)
system Single commissioning for each fan and
□Yes □No
commissioning of subsystem
Completion for inspection and adjustment
of various air dampers and baffle with □Yes □No
acceptable quality
Completion for single commissioning and
interlock protection test on flame scanning □Yes □No
cooling fan with acceptable quality
Flame scanning
(3) Completion for commissioning of CCTV
system □Yes □No
system ,putting into service at any time
Qualified commissioning for the flue-gas
□Yes □No
temperature probe of boiler
Electrostatic Completion for installation of electrostatic
(4) precipitator precipitator and heat insulation with □Yes □No
system acceptable quality
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Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 38 of 55
Verified Rema
No. Items Requirements Result
by rks
Qualified for air-flow distribution test,
pressure rising and rapping test on □Yes □No
electrostatic precipitator
Completion for ash bucket heating device of
the electrostatic precipitator and inspection □Yes □No
with acceptable quality
Completion for single trial use and
installation of oil storage and stokehold fuel □Yes □No
oil system as well as heat insulation work
Completion for hydrotest of the stokehold
fuel oil system and qualification for water □Yes □No
and steam flushing
Completion for installation of steam
blowpipe of fuel oil system and adjustment □Yes □No
on blowing valve
(5) Fuel oil system Completion for motorized valve and
pneumatic valve adjustment of fuel oil □Yes □No
system with acceptable quality
Qualification for the simulation test in
related interlock protection(MFT AND
OFT) of the fuel oil system
Completion of the advancing and regressing
□Yes □No
test for oil gun and high-energy igniter
Completion for each flame check static
□Yes □No
commissioning
Installation of boiler proper and heat
(6) Boiler proper insulation are completed with acceptable □Yes □No
quality
Hydrotest of the boiler is completed with
□Yes □No
qualified acceptance.
Water drainage, bleeding, regular draining,
continuous draining, bottom heating,
installation of nitrogenization system and
□Yes □No
heat insulation are completed fully. All
motorized valve commissioning has been
completed with acceptable quality
The installation for the hydraulic block plate
of the main steam pipeline at the
□Yes □No
superheater outlet has been completed and
shall be removed after hydrotest.
After hydrotest , all the hydraulic valve
cores of the each safety valve for drum and
superheater are removed, restoring formally
□Yes □No
and complying with the requirement of
manufacturer. The hydraulic block plate
shall be dismantled.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 39 of 55
Verified Rema
No. Items Requirements Result
by rks
The spring supports and hangers for
steam-water pipeline are complete and the □Yes □No
pin is removed, with free stress
Motorized and pneumatic valve for each
steam-water pipeline are adjusted to be □Yes □No
qualified
The expansion system of boiler proper is
inspected jointly by each party to be normal
□Yes □No
and the expansion indicator is complete and
adjusted to zero.
Staircase, platform and rail of the boiler are
complete with sufficient lighting and free of □Yes □No
sundries.
After pickling of boiler is completed, the
inner arrangement for the steam drum
should be cleaned to normal, the drum is
□Yes □No
closed and the temporary facilities should
be removed, the formal system has been
restored.
The steam drum water-level gauge has been
installed properly, and the SRTV has been □Yes □No
adjusted and can be put into application
Boiler water sampling and dosing system
have been installed with acceptable
□Yes □No
quality ,providing with the operation
condition
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
□Yes □No
completed. The installation and heat
insulation of temporary back-flush pipes at
steam side of superheater (reheater)
desuperheater are completed with
acceptable quality.
All the manhole doors and inspection holes
□Yes □No
in the boiler proper are complete and closed.
The inspection for burner installation and
coal flame checking commissioning under
□Yes □No
cold state are qualified, with normal
operation conditions.
Installation for slag pit (including the
Ash and cinder furnace bottom sealing), slag tank and
(7) □Yes □No
handling system rotating equipment are completed with
acceptable quality.
Verified Rema
No. Items Requirements Result
by rks
qualified and can be put into operation.
The installation and commissioning work
for the dedusting system equipment are
completed, the logical commissioning for □Yes □No
dedusting program control are completed,
providing with operation conditions.
Installation and trial use of each single
equipment are completed with acceptable □Yes □No
quality.
Coal handling
(8) The interlock protection test is qualified. □Yes □No
system
Defects found in system commissioning
have been eliminated, providing with coal □Yes □No
feeding conditions.
Completion of pipe installation and heat
□Yes □No
insulation
Completion of installation and
Soot blower commissioning of motorized and pneumatic □Yes □No
(9)
system valve
It can be put into operation at any time after
completion of soot blowing test of air □Yes □No
preheater.
Completion of installation and heat
□Yes □No
insulation
Qualified for commissioning of sealing fan □Yes □No
Primary air leveling is qualified □Yes □No
Calibration of the air volumn at the inlet of
□Yes □No
coal mill is qualified
Completion of coal mill lubricating oil
□Yes □No
system commissioning
Coal pulverizing
(10)
system Completion of cold state commissioning for
□Yes □No
the coal mill
Completion of trial use of coal mill and coal
feeder, providing with the commissioning □Yes □No
condition;
Completion of the transmission test for
□Yes □No
baffle system and damper
Calibration for coal feeder weighing device
□Yes □No
is qualified.
Completion of installation and heat
□Yes □No
insulation
(11) Air heater system
Completion of trial use of single equipment. □Yes □No
The interlock protection test is qualified. □Yes □No
(12) Compressed air
Completion of trial use for the single and □Yes □No
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 41 of 55
Verified Rema
No. Items Requirements Result
by rks
subsystem of instrument and service air
compressor;
Completion of installation for instrument
and service air gasholder as well as □Yes □No
system checkout of safety valve;
Qualified for instrument and service air
□Yes □No
lines blowing
The interlock protection test is qualified. □Yes □No
Completion of installation □Yes □No
All fire-fighting equipments are complete,
and watering test for firefighting water is □Yes □No
Fire protection
(13) qualified, being in reservation state.
water system
Fire-fighting equipments are complete in
control room, electronic room and fuel oil □Yes □No
system
Completed installation and qualified
□Yes □No
Industrial water hydraulic pressure
(14)
system It can be put into operation after completion
□Yes □No
of trial use.
It can be put into operation after the
completion for installation commissioning □Yes □No
of boiler
Auxiliary steam Completion of installation and heat
(15) □Yes □No
system insulation for auxiliary steam system
The motorized valve of auxiliary steam
system is qualified and can be put into □Yes □No
operation.
Completion of isolation of public with 2#
(16) Isolation □Yes □No
unit
It is provided with the feature of continuous
□Yes □No
Chemistry water chemical water supply
(17)
system Completion of commissioning for water
□Yes □No
charging system
Condenser and hot well is qualified after
cleaning; it is qualified for the condensing
(18) Steam Turbine pump via commissioning, the blowing of □Yes □No
system is qualified and can supply the water
for deaerator.
Inner of deaerator has been cleaned. After
blowing, steam-heated pipelines are
□Yes □No
returned to normal and can be heated and
applied.
Verified Rema
No. Items Requirements Result
by rks
returned to normal and can be put into
operation.
Measures to prevent air from entering the
turbine has been implemented and is □Yes □No
qualified after inspection.
Commissioning for steam turbine vacuum
system is completed and can be put into □Yes □No
operation;
Commissioning for lubrication oil system of
steam turbine, sealing oil system, and
jacking oil system are completed. Turning □Yes □No
device system is normal and can be put into
operation.
The main steam pipeline of steam turbine,
reheating and recooling pipeline of cold and
hot section as well as the high and low
□Yes □No
pressure bypass draining valve are
confirmed to be qualified and can be put
into operation.
The commissioning for temperature
measuring point of steam turbine cyliner
□Yes □No
has been checked and can show accurate
temperature of the cylinder..
All steam bleeding electric intercept valves
are tested and qualified, with strict □Yes □No
closeness.
Drain introduced into the condenser has
□Yes □No
been reliably isolated.
Low voltage turbine water spray can be put
□Yes □No
into operation.
2 Electrical and Thermal Regulating conditions
Completion of interlock test on flame
□Yes □No
scanning cooling fanl
Completion of inspection on furnace
□Yes □No
blowing condition
Completion of MFT test and interlocking
□Yes □No
Boiler test after MFT
FSSS(including
(1) OFT test and completion of interlocking test
fuel oil and coal □Yes □No
after OFT
filling part )
Completion of fuel oil leakage test □Yes □No
Completion of oil gun fueling management
□Yes □No
test
Completion of coal feeder and coal mill
□Yes □No
control as well as interlocking test
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 43 of 55
Verified Rema
No. Items Requirements Result
by rks
Air preheater(A/B) launching and tripping
conditions, programmed start, programmed □Yes □No
stop
IDF(A/B) launching and tripping
conditions, programmed start, programmed □Yes □No
stop
Forced draft fan (A/B) launching and
tripping conditions, programmed start, □Yes □No
Sequential control programmed stop
of auxiliary
(2) engine and Primary air fan (A/B) launching and
interlock and tripping conditions, programmed start, □Yes □No
protection tests programmed stop
Sealing fan (A/B) launching and tripping
□Yes □No
conditions
Coal mill(A/B/C/D/E) launching and
tripping conditions, programmed start, □Yes □No
programmed stop
Feeder (A/B/C/D/E) launching and tripping
□Yes □No
conditions
I&C measuring
The calibration is complted, the indication
(3) points and meter □Yes □No
is accurate
of DAS system
Protection, alarm
as well as It can give alarm after completion of
(4) □Yes □No
acoustic and light transmission commissioning
signals
Emergency power
(5) Applicable □Yes □No
supply
DCS two -way
(6) Applicable □Yes □No
power
Blowing system
(7) Completed for drawing □Yes □No
control drawing
3 Environmental conditions
Traffic Unclogging □Yes □No
(1)
Light Sufficient □Yes □No
Communication
(2) Convenient and unobstructed □Yes □No
equipments
(3) Fire apparatus Sufficient and in stand-by condition □Yes □No
It should be debugged to meet the
(4) A/C system □Yes □No
requirement of the computer equipment
Only after debugged and tested, it can be
(5) Boiler staircase □Yes □No
put into application.
4 Other requirements
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 44 of 55
Verified Rema
No. Items Requirements Result
by rks
Organizing the united major inspection on
construction, Owner, production and
(1) Inspection □Yes □No
commissioning; the problems found should
be dealt completely.
Completion of reparation for production
□Yes □No
commissioning
Qualified training test of the operators □Yes □No
Production
(2) The operation scheme and system drawing
preparation □Yes □No
have been reviewed and approved.
Operation instrument and running log are
□Yes □No
complete.
Chemicals and material preparation for trial
□Yes □No
Resources use are in order
(3)
preparation Chemical water, fuel oil and coal design are
□Yes □No
prepared sufficiently.
Overhaul tools
(4) Prepared □Yes □No
and materials
Commissioning
control and
(5) Sound and clear division of work □Yes □No
organization
system
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 45 of 55
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) 0702-00-M-01-LB-002
DWG No.
PT.PLN(PERSERRO)
PT REKADAYA
JAVA MANAJEMEN
ELEKTRIKA
KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE
ENERGY
SiChuan Electric Power DETAIL
PLTU 1 Jatim-Pacitan
Commissioning & Test DESIGN
(2×315MW) Project
Institute STAGE
Approval Check Procedure of Relief Valve and Steam
Review Design Tightness System
Date SCCTI-TS-GL-C REV
N/A A
Scale DWG No. S-017-2009A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 2 of 18
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
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
9. 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
10. APPENDIX ............................................................................................................................... 13
10.1 Appendix 1 Commissioning Condition Checklist.............................................................. 14
10.2 Appendix 2 Setting Record of Safety relief Valves and ERV ............................................ 17
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 3 of 18
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.
The information contained in the above list sources form the Instruction Manual of Dongfang
Boiler of DEC (No. 97M-YM)
feed water, fuel oil, ash and cinder removal, etc. has been completed.。
6.1.3 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.
6.2 Conditions that must be available with electrical and I&C
(1) 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.
6.3 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..
6.4 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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 6 of 18
(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.
◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 7 of 18
◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning;
8. Commissioning Procedure
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:
(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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 8 of 18
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) 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.
8.1.3 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
(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.
8.2.2 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;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 9 of 18
(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.
8.2.3 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.
8.2.4 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.
(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;
8.2.5 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
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 10 of 18
(4) Setting of safety relief valves and calibration of pressure gauges of DCS shall be based
on the local master gauge.
8.2.6 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.
8.2.7 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.
8.2.8 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..
8.2.9 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.。
8.3 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:
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 11 of 18
For the setting values of the safety relief valves refer to Appendix 2
9. Safety Measures
9.1 Safety Rules for Commissioning
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 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.
9.1.4 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 Personal Risk and Preventative Measures
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 Equipment Risk and Preventative Measures
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 12 of 18
machines.
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.
10. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 14 of 18
state.
(3) Steam and Water System Electrical and heat power
engineering instrument have □Yes □No
been calibrated and prove to
be accurate.
(4) Master Gauge To be calibrated for □Yes □No
satisfaction
3 Environmental Conditions
(1) Site All work has been completed.
Platform Free of foreign matters. □Yes □No
Passage To be kept smoothly.
(2) Temporary Platform and The construction work
Safeguards finished and prove to be safe □Yes □No
and reliable.
(3) Lighting Sufficient, and temporary
lighting points added when □Yes □No
necessary.
(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, □Yes □No
commissioning, etc. should
be carried out and any
problems discovered should
be solved.
(2) Production Preparation Trial operation has well been □Yes □No
prepared.
Operators have well been
trained and have passed the □Yes □No
exam.
The operating standard and
applicable system diagram □Yes □No
has examined and approved.
Tools and forms of
operational logs for the □Yes □No
operation have well been
prepared.
(3) Resources Preparation Chemicals and materials
needed for the trial operation □Yes □No
have well prepared.
Sufficient chemical water,
fuel oils and designed coals □Yes □No
have well been prepared.
(4) Special Tool Kit for the Have well been prepared. □Yes □No
Calibration
(5) Overhaul Tools and Ready for use □Yes □No
Materials
(6) Command Organization To be sound and with definite □Yes □No
for Trail Operation duties and responsibilities.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 16 of 18
1 1749WB 19.57
2 1749WB 19.96
3 1749WB 20.16
SH safety relief valves parameter
Setting pressure
Popping pressure Return pressure
Service Description (MPa) Remarks
(MPa) (MPa)
1 1730WD 18.25
2 1730WD 18.28
ERV
Setting pressure Popping pressure Return pressure
Service Description Remarks
(MPa) (MPa) (MPa)
1 3538W 18.07
RH inlet safety relief valves parameter
Setting pressure
Return pressure
Service Description (MPa) Popping pressure(MPa) Remarks
(MPa)
1 1785WB 4.37
2 1785WB 4.37
3 1785WB 4.50
4 1785WB 4.50
RH outlet safety relief valves parameter
Setting pressure Popping pressure Return pressure
Service Description Remarks
(MPa) (MPa) (MPa)
1 1765WD 4.01
2 1765WD 4.325
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HL-004
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Review Design
Procedure of Cold State Aerodynamic Field
Date Scale N/A DWG No. SCCTI-TS-GL-CS-018-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 2 of 20
Table of Contents
1. PURPOSE ........................................................................................................................................... 3
2. SCOPE ................................................................................................................................................ 3
9. SAFETY MEASURES..................................................................................................................... 11
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;
coordinates.
6.13 Burning powder online device is installed and equipment manufacturer has arrived at site and
is prepared for calibration.
◆ 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;
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 6 of 20
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;
8. Commissioning Procedure
8.1 Test Content and Method
8.1.1 Preparation for Testing
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 8 of 20
(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:
Calculate the ratio between secondary air speed and perimeter air speed with
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A 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).
BMCR BMCR
Operating conditions
Five coal mills Four coal mills
Air speed
operating operating
Air speed of primary air nozzle
28 28
m/s
Air speed of secondary air nozzle
42 45
m/s
Air speed of perimeter air nozzle
35 35
m/s
Concentration of primary air
pulverized coal 0.504 0.630
kg/kg
Air speed of cold state burner nozzle will be as follows when simulate above
conditions:
Table
BMCR BMCR
Five coal mills Four coal mills
operating operating
Air speed of primary air nozzle
18 18
m/s
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 10 of 20
Operating
Description
condition
Rated condition, namely pulverized coal for all five layers
#1 input, five coal pulverizing systems operating, top
counter-tangent secondary damper fully open.
Pulverized coal for four layers input, four coal pulverizing
#2 systems operating, top counter-tangent secondary damper fully
open.
Pulverized coal for four layers input, four coal pulverizing
#3 systems operating, top counter-tangent secondary damper fully
open.
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 11 of 20
9. Safety Measures
9.1 Safety rules for commissioning
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 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 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.
9.2 Personal Risk and Preventative Measures
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 12 of 20
Remar
No. Items Requirements Result Verified by
ks
Time
Elevation (mm) 1 2 3 4 1 2 3 4
Time
A1
A2
A3
A4
B1
B2
B3
B4
C1
C2
C3
C4
D1
D2
D3
D4
E1
E2
E3
E4
Burner
燃烧器
23100
19600
Grid
网格铁丝wire
18100
Stay
拉线螺母nut
Grid 网格截面
section
Scaffold
脚手架踏板
step
脚手架踏板
Scaffold step
12600
Burner燃烧器喷口
nozzle
1000mm
100mm Grid
网格铁丝 wire 150mm gap between steps at this point
此处踏板间隙150mm
Manhole
人孔
Coordinat
e坐标灯
lamp Coordinate
坐标灯 lamp
Scaffold
脚手架踏板 step
Scaffold
脚手架
600×1000mm
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.
PLTU 1 Jatim-Pacitan (2×315MW) Project
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-G-01-H-001
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power DESIGN STAGE
PLTU 1 Jatim-Pacitan (2×315MW)
Commissioning & Test Institute
Project
Approval Check Procedure of Energy Source and Resource
Review Design Economizing
Date Scale N/A DWG No. SCCTI-TS-GL-CS-001-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 2 of 8
Table of Contents
1 PURPOSE ......................................................................................................................................................... 3
2. SCOPE .............................................................................................................................................................. 3
7. TECHNICAL MEASURES............................................................................................................................. 5
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
BMCR
Item Unit ECR condition
condition
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.
◆ 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;
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 6 of 8
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,
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 7 of 8
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.
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-G-01-H-002
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Review Design Procedure of Boiler Integral Start-up
Date Scale N/A DWG No. SCCTI-TS-GL-CS-002-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 2 of 28
Table of Contents
1. PURPOSE ............................................................................................................................................ 3
2. SCOPE ................................................................................................................................................. 3
3. PREPARATION BASIS....................................................................................................................... 3
10. APPENDIX................................................................................................................................ 17
1. 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) Manual of boiler performance and structure;
(4) Boiler erection manual;
(5) Boiler operation manual;
(6) Manual of combustion equipment.
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 BMCR BRL
Description
Unit BMCR 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
Outlet flue gas temp. of furnace ℃ 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
℃ 363/355 364/356
(primary /secondary)
Fuel consumption t/h 163.91 155.28
Boiler efficiency % 93.04 92.94
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 5 of 28
Air
Air-to coal Air Flowrate Temperature Resistance
No. Item
Ratio (%) (m/s) (Pa)
(℃)
1 primary airc -- 28 65 1900
2 secondary air -- 45 346 1000
3 Surrounding air -- 35 346 --
4 Furnace air leakage -- -- -- --
煤种
Worst Range of
No. Item Symbol Unit DSG'D Coal Change in
Coal Type Coal Quality
type
Carbon content as received
1 Car % 47.65 45.2 41.25~49.4
basis
2 As-received basis hydorgen Har % 3.36 3.15 3.375~4.55
3 As-received basis oxygen Oar % 14.49 11.7 7~16.25
4 As-received basis nitrogen Nar % 0.77 0.70 0.375~0.975
5 As-received basis sulfer Sar % 0.23 0.25 0.1~0.23
6 As received basis ash content Aar % 3.5 4 3~6
As received basis total
7 Mar % 30 35 25~35
moisture
Water content as air dried
8 Mad % 20 25 15~25
basis
Dry ash-free basis volatile
9 Vdaf % 50 46 42~67.8
component
Fixed carbon content as
10 FCar % 30 -- 28~42
received basis
Low heat value as received KCal
11 Qnet,ar 4200 3900 3900~4500
basis /kg
12 Grindability coefficient HGI 45 45 45-65
13 Fineness of pulverized coal R90 32
14 Ash fusing point
(1) Deformation temperature DT °C 1150 1150 1150
(2) Softening temperature ST °C 1200 1200 1200
(3) Fusion temperature FT °C 1300 1300 1300
commissioning of this system according to contents listed in Annex 1 (Integral startup and
Commissioning Condition Checklist) and make well the records.
6.1 Conditions that must be available with machinery provisions
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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Procedure
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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
(3) Startup and shutdown conditions and interlock relations of induced draft fans, forced
draft fans and primary fans
(4) Interlock relations between dampers;
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.
8. Commissioning Procedure
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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Procedure
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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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Procedure
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(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
(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;
(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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Procedure
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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;
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.
(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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9. Safety Measures
9.1 Safety rules for commissioning
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 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.
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.
9.1.4 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 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。
9.2.2 Commissioning personnel shall observe combustion state inside furnace properly to avoid
scald.
9.3 Equipment Risk and Preventative Measures
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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Verified
No. Items Requirements Result Remarks
by
1. Mechanical system conditions
The installation and insulation are
□Yes □No
complete
The hydrostatic test and air pressure test
□Yes □No
have been completed.
(1) Boiler proper
Scaffolds, litter and foreign matters have
been removed from furnace and flue
gas& air ducts, all personnel have □Yes □No
escaped and all manholes and access
holes have been closed.
The installation and insulation are
□Yes □No
complete
Flue gas &air
(2) Commissioning of induced draft fans,
systems
forced draft fans, primary fans and air □Yes □No
preheaters are complete.
The installation and insulation are
□Yes □No
complete
The systems are complete with all
Steam and
(3) supports and hangers, and pins have □Yes □No
water system:
been removed from spring hangers.
The hydrostatic test is complete and
□Yes □No
blind plates have been removed.
The installation and insulation are
□Yes □No
complete
Fuel oil system Individual commissioning of all oil
(4) □Yes □No
pumps has been successfully completed
The oil piping has been successfully
□Yes □No
purged
The installation and insulation are
□Yes □No
complete
Static commissioning of coal mills and
Pulverizing □Yes □No
(5) feeders are complete.
plant
Individual commissioning of coal mills,
feeder and auxiliary facilities are □Yes □No
complete.
Installation, individual commissioning
of .all equipments and acceptance check □Yes □No
are complete
Coal handling
(6) Ready to transfer coal to coal bunker at
system □Yes □No
any time
The raw coal bunkers have been
□Yes □No
thoroughly cleaned.
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Ash blowimg The piping has been purged with steam □Yes □No
(10)
Systems Static commissioning of all ash blowers
□Yes □No
has been successfully completed.
Ready for operation □Yes □No
Auxiliary systems, such as the dosing,
sampling, periodic and continuous
Auxiliary
(11) blowdown, drain, vent, back flushing □Yes □No
system
and inert gas flushing systems, have
been installed and insulated.
Boiler bottom
The systems have been installed and
(12) steam heating □Yes □No
insulated and are ready for operation.
system
Boiler All expansion indicators have been
(13) expansion installed as per the design and reset to □Yes □No
system; zero position.
Adequate fire fighting material are
Fire protection available and fire water systems have
(14) □Yes □No
system been installed and commissioned and
ready for use
Industrial water The systems have been installed and
(15) □Yes □No
system; commissioned and ready for use
2 Electric, instrument and control condition
Motor-driven
The static commissioning is complete
and pneumatic
(1) and valves and dampers can move freely □Yes □No
valves and
in correct direction.
dampers
Static commissioning are complete and
(2) Alarm systems □Yes □No
indication is correct
Emergency The pushbuttons are functional and
(3) □Yes □No
pushbutton for wired correctly.
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rotating
machinery
Commissioning is complete, startup and
Auxiliaries
(4) stop logic are correct and equipments □Yes □No
PLC system
can operate normally
The static commissioning is complete,
(5) FSSS □Yes □No
logic is correct and movement is reliable
Static commissioning is complete and
the name and indication of all data □Yes □No
Data points are correct.
acquisition and
(6) Static commissioning of the industrial
supervisory
control system CCTV systems and flame detector
□Yes □No
systems has been completed and they
are ready for operation at any time.
Automatic
Static commissioning is complete and
weighing
(7) the systems are able to measure and □Yes □No
system of coal
indicate coal weight accurately.
feeders
Furnace gas Static commissioning and setting are
(8) temperature complete and the probes can move □Yes □No
probe freely.
Program
The static commissioning has been
control of ash
successfully completed and simulation
(9) blowing and □Yes □No
tests indicate that the relations are
periodic
correct and movement is reliable.
blowdown
Combined
interlock test
covering the The simulation test is complete, logic is
(10) □Yes □No
turbine, boilers correct and movement is reliable
and electrical
systems
3 Civil works
Clear
Road
(1) Adequate normal and emergency □Yes □No
Lighting
lighting facilities is available
(2) Fire apparatus Adequate □Yes □No
Communicatio Easy to use, adequate fire fighting
(3) □Yes □No
n equipments apparatus are available
4 Commissioning items which should be completed
Boiler proper Has been pickled
Temporary Has been washed with alkali
(1) □Yes □No
systems of The normal system configuration has
boiler front-end been resumed
Dampers of
(2) flue gas and air Commissioning is complete □Yes □No
systems as well
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 21 of 28
steam and
water valves
Cold-state The leveling and air flow calibration are
(3) □Yes □No
ventilation complete
Boiler piping
blowing. Fulfilled
(4) □Yes □No
Temporary Have been removed
system
Auxiliary
(5) sequential Have been checked and tested □Yes □No
control
(6) FSSS Have been checked and tested □Yes □No
Emergency
pushbutton for
(7) Have been checked and tested □Yes □No
rotating
machinery
(8) Alarm signal Have been checked and tested □Yes □No
5 Other conditions
Chemical water In good order and ready to supply
(1) □Yes □No
system demineralized water as per the design
Compressed air In good order and ready to supply
(2) □Yes □No
system compressed air as per the design
Station service In good order and ready to supply power
(3) □Yes □No
system as required
Lighting and
(4) communication In good order and ready to communicate □Yes □No
system;
Central A/C Have been commissioned and read for
(5) □Yes □No
system operation at any time
Time Condition
Description Unit A B C D E
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
Appendix 4 Record for Boiler MFT (OFT) and Integral Interlock Test
(1) Control power failure: Power supply to the FSSS cabinet fail
(2) Two forced draft fans stop
(3) Two induced draft fans stop
(4) Manual MFT
(5) Drum level above +250mm (two-out of-three, at least 2s)
(6) Drum level below -250mm (two-out of-three, at least 2s)
(7) High furnace draft (2 out of 3), set value +1960Pa without time delay
(8) Low furnace draft (2 out of 3), set value -1960Pa without time delay
(9) Air flow entering furnace <30% for at least 60s
a. Load >40%, steam turbine tripped
(10) 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)
(11) Coal mills at any layer is running, all primary air fans stop and no oil layer is operating
(12) 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.
(13) 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.
(14) 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
¾ 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.
(15) Low flame scanning cooling air pressure, <5.5kPa (10s time delay, 2 out of 3)
(16) All flame scanning cooling fans stop
(17) 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
(18)
complete)
(19) Generator transformer protection is triggered
3. Equipment interlocked with MFT
(1) 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,
(2)
disable oil gun purging and close all purge valves
(3) Close oil supply fast valve of oil manifold
(4) Close motor-driven valves on oil return mains
(5) Trip all coal pulverizers
(6) Trip all coal feeders
(7) Close all mill outlet air dampers;
(8) Close cold and hot air quick-closing valves as well as cold and hot air regulating valves of all coal mills.
(9) Trip all primary fans (including sealing air fans)
(10) 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
(11)
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
(12)
maintain a normal furnace pressure
¾ Furnace FSSS natural draft (when stopping of induced and forced draft fans causes MFT, the
(13) 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
¾ 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)
(14) Trip MFT relay (fail-trip)
Main and auxiliary desuperheating water valves of superheater systems are closed, all regulating valves
(15)
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
(16)
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
(17)
service.
(18) Send MFT signal to the CCS, SCS and ETS systems
(19) Steam turbine tripped
(20) Generator transformer protection tripped
(21) The swinging mechanism of burners moving to horizontal position automatically
(22) Electrostatic precipitators tripped
4. Logic check for FSSS hard-wired control circuit
(1) All primary air fans tripped
(2) All mills tripped
(3) All coal feeders tripped
(4) Fuel oil return electric valves closed
(5) Quick-closing fuel oil supply valves closed
(6) All angle oil valves of oil guns fully closed
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HH-001
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Procedure of Fuel Cutoff and Stabilizing
Review Design
Burning
Date Scale N/A DWG No. SCCTI-TS-GL-CS-003-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
调试程序
Procedure of Fuel Cutoff and Stabilizing Burning REV A
Commissioning
Procedure SCCTI-TS-GL-CS-003-2009A Page 2 of 15
Table of Contents
1. PURPOSE ............................................................................................................................................ 3
2. SCOPE ................................................................................................................................................. 3
3. PREPARATION BASIS............................................................................................................... 3
10. APPENDIX................................................................................................................................ 10
1. 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 Manual of boiler performance and structure;
3.3 Manual of combustion equipment;
3.4 Manual of coal mill.
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.
Feature Data of Burner (design coal type/BMCR load)
basis)
10 Net calorific value Qnet.ar Kcal/kg 4200
11 Hardgrove grindability
HGI 45
coefficient
12 Ash deformation temperature DT ℃ 1150
13 Ash softening temperature ST ℃ 1200
14 Ash fusion temperature FT ℃ 1300
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.
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
Procedure of Fuel Cutoff and Stabilizing Burning REV A
Commissioning
Procedure SCCTI-TS-GL-CS-003-2009A Page 9 of 15
9. Safety Measures
9.1 Safety rules for commissioning
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 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.
9.1.4 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 Personal Risk and Preventative Measures
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
调试程序
Procedure of Fuel Cutoff and Stabilizing Burning REV A
Commissioning
Procedure SCCTI-TS-GL-CS-003-2009A 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
调试程序
Procedure of Fuel Cutoff and Stabilizing Burning REV A
Commissioning
Procedure SCCTI-TS-GL-CS-003-2009A Page 11 of 15
Inspection of firing in
3 furnace
firing stable and flame clear □Yes □No
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project
调试程序
Procedure of Fuel Cutoff and Stabilizing Burning REV A
Commissioning
Procedure SCCTI-TS-GL-CS-003-2009A Page 12 of 15
Time Condition
Name Unit Data Name Unit Data
Unit load MW Furnace negative pressure Pa
Oxygen concentration at furnace
Main steam flow T/H %
outlet
Oxygen content at air preheater
Main steam pressure MPa %
outlet
Flue gas temperature at air
Main steam temp. ℃ ℃
preheater A inlet
Flue gas pressure at air preheater
Drum pressure MPa ℃
A outlet
Flue gas temperature at air
Drum level mm ℃
preheater B inlet
Flue gas temperature at air
Feed water flow T/H ℃
preheater B outlet
Feed water pressure MPa Outlet flue gas temp. of furnace ℃
Flue gas temperature at
Temp. of feed water ℃ ℃
economizer inlet
First step temp. reduction water
T/h Temp. of flue gas ` ℃
flow, A Side
First step temp. reduction water
T/h Flow of reheated steam T/h
flow, B Side
Second step temp. reduction
T/h Reheat steam inlet pressure MPa
water flow, A Side
Second step temp. reduction
T/h Reheat steam outlet pressure MPa
water flow, B Side
Reheat steam inlet and outlet
A/B IDF current A ℃
temperature
Reheat desuperheating water flow
A/B IDF static blade opening % T/H
at Side A/B
Steam temperature upstream of
A IDF inlet air pressure KPa ℃
Stage 1 desuperheating water
Steam temperature downstream
B IDF inlet air press KPa ℃
of Stage 1 desuperheating water
Steam temperature upstream of
A FD fan current A ℃
Stage 2 desuperheating water
Low-temperature superheater wall
B FD fan current A ℃
temperature
A FD fan dynamic blade Platen superheater wall
% ℃
opening temperature
B FD fan dynamic blade High-temperature superheater
% ℃
opening wall temperature
Low-temperature reheater wall
A FD fan outlet air pressure KPa ℃
temperature
PLTU 1 Jatim-Pacitan(2×315MW) Project
调试程序
Procedure of Fuel Cutoff and Stabilizing Burning REV A
Commissioning
Procedure SCCTI-TS-GL-CS-003-2009A Page 13 of 15
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HH-002
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Review Design Procedure of Burning Commissioning
Date Scale N/A DWG No. SCCTI-TS-GL-CS-004-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Table of Contents
1. PURPOSE ..........................................................................................................................................................3
2. SCOPE ...............................................................................................................................................................3
3. PREPARATION BASIS.....................................................................................................................................3
8. COMMISSIONING PROCEDURE...................................................................................................................7
9. SAFETY MEASURES.......................................................................................................................................8
1. 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.
Generator output MW
Outlet
MPa 3.80 3.438 3.38 2.53 1.76
Reheat pressure
steam
Inlet
℃ 329 322 320 313 318
temperature
Outlet
℃ 541 541 541 541 515
temperature
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.
◆ Be responsible for temporary coordination of local control and instruments and connection
terminals.
7.3 Responsibilities of Equipment Manufacturer
◆ 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;
◆ 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;
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;
8. 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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 Safety rules for commissioning
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 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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
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 Personal Risk and Preventative Measures
9.2.1 Flame observers shall communicate frequently with CCR operators. Flame observers shall use correct
methods to avoid burns.
9.3 Equipment Risk and Preventative Measures
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Remar
No. Items Requirements Result Verified by
ks
Flue gas and air Fully opened and closed to their limit
□Yes □No
baffle, steam and positions;
1 water valve Close and open in correct direction □Yes □No
Operation test
Correct status indication. □Yes □No
Primary air evenness measurement is
□Yes □No
complete
Cold ventilation Calibration of secondary air flow
2 □Yes □No
test measurement devices is complete
Calibration of air flow meters at coal
□Yes □No
mill inlets is complete
The auxiliary part has been tested; □Yes □No
Interlock, The FSSS test is complete □Yes □No
protection,
3 sequential control, The interlock test of valves and dampers
□Yes □No
audible and visual is complete
alarm test The relevant audible and visual alarm
□Yes □No
tests are complete
The static commissioning of burners are
4 Burners □Yes □No
complete;
The static commissioning of fuel oil
□Yes □No
systems is complete;
Separate operation, program-controlled
5 Fuel oil system startup and shutdown test of all oil guns □Yes □No
are complete;
Interlock protection test of the fuel oil
□Yes □No
systems are complete
The static commissioning is complete □Yes □No
The operation test of dampers are
□Yes □No
6 Pulverizing plant complete
All interlock and protection tests are
□Yes □No
complete
Static commissioning of ash blowers are
□Yes □No
complete;
Ash blowing Static commissioning of all ash blower
7 □Yes □No
Systems PLCs are complete;
The ash blowing steam supply safety
□Yes □No
valves have been set.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Remar
No. Items Requirements Result Verified by
ks
The valve operation tests
□Yes □No
are complete
The interlock test is
□Yes □No
8 Ash handling system complete;
The PLC test is complete; □Yes □No
Individual trial run is
□Yes □No
complete
Flame scanning cooling air The interlock test is
9 system complete;
□Yes □No
Prepared
17 Test instruments and meters □Yes □No
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) 0702-00-M-01-HLB-001
DWG No.
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
Sichuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW)
DESIGN
Commissioning & Test Institute Project
STAGE
Approva Check
Commissioning Procedure of Induced Draft Fan
l
System
Review Design
Date Scale DWG SCCTI-TS-GL-CS-005-200 REV
N/A A
No. 9A
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 2 of 22
Table of Contents
1. PURPOSE ........................................................................................................................................... 3
2. SCOPE ................................................................................................................................................ 3
9. SAFETY MEASURES..................................................................................................................... 15
10.4 Appendix 4 Control Damper Commissioning Record of IDF and Its System . 22
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 3 of 22
1. 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 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
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.
◆ 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;
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
8. Commissioning Procedure
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;
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 7 of 22
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
8.2.2.3 Inspection on tripping condition for the protection interlinking of induced draft fan
(9)
The furnace pressure of FSSS is low;
(10) Emergency button action;
After the induced draft fan A operates for 60s, two cooling
(11)
fans suspends completely;
The stationary blade is greater than 15%, and the induced
(12)
draft fan A is stalling.
(13) Air preheater A suspends
Tripping condition of induced draft fan B
After the induced draft fan B operates for 60s, the electric
(1)
damper at the outlet of induced draft fan B is closed;
After the induced draft fan B operates for 60s, the electric
(2)
damper at the inlet of induced draft fan B is closed;
The bearing temperature of the induced draft fan B is high
(3)
high.
(4) The motor bearing temperature of the induced draft fan B
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 10 of 22
is high high.
The vibration speed of motor bearing for the induced draft
(5)
fan B is high high.
The vibration of bearing in X-direction at the driving end
(6)
of induced draft fan B is high high
8.2.2.5 The damper at the inlet and outlet of induced draft fan as well as the interlock test of
stationary blade
8.2.2.6 Interlock test for the interconnection valve at the outlet of electric precipitator
8.2.2.7 Procedure on sequence control startup and shutdown for the induced draft fan
8.3 Commissioning and shutdown of the induced draft fan and system
8.3.1 Check to be completed prior to system startup
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;
8.3.2.5 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 Safety Rules for Commissioning
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 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.
9.1.4 All professional staffs shall be on respective duties during the whole commissioning to
guarantee the safe operation of equipments.
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 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;
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 16 of 22
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
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 17 of 22
ELEC PRECIPITATOR
X0HNA13AA001XB INTERCONNECTING MOTOR
SHUT-OFF DAMPER
10.4 Appendix 4 Control Damper Commissioning Record of IDF and Its System
Control Damper Commissioning Record of IDF and Its System
Commissioning Procedure
Owner’s DWG
PT.PLN(PERSERRO)
No.
0702-00-M-01-QH-001
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE
ENERGY
SiChuan Electric Power DETAIL
PLTU 1 Jatim-Pacitan (2×315MW)
Commissioning & Test DESIGN
Project
Institute STAGE
Approval Check
Review Design Procedure of Start-up Boiler
Date Scale N/A DWG No. SCCTI-TS-GL-CS-006-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 2 of 40
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 Safety rules for commissioning ........................................................................ 28
9.2 Personal Risk and Preventative Measures........................................................ 29
9.3 Equipment Risk and Preventative Measures .................................................... 29
10. Appendix .......................................................................................................... 30
10.1 Appendix 1 Commissioning Condition Checklist............................................ 31
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 3 of 40
1. 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 Check the reliability of electric and I&C interlock protection and signal device.
1.3 Check the operation conditions of equipment. Examine performance of system so as to find
out and eliminate possible defects.
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
1 Boiler Parameter
2 Technical Performance
(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.
6.1.5 Compressed Air System
(1) Instrument& service air compressors have passed commissioning individually or as a
subsystem and are ready for use.
6.1.6 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.
6.1.7 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.
6.1.8 Chemical Water System
(1) The chemical system is able to supply water continuously.
(2) Commissioning of make-up water systems has been completed.
6.2 Conditions that must be available with electrical and I&C
(1) 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.
(2) Sequence control, interlock and protection test of each auxiliary device has been
completed;
1) Starting conditions, tripping conditions, program-controlled startup and
program-controlled shutdown of forced draft fans (A/B)
2) Starting conditions, tripping conditions, program-controlled startup and
program-controlled shutdown of water feed pump (A/B)
(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,
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 7 of 40
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) 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.
6.3 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.
6.4 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. 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;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 8 of 40
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;
8. Commissioning Procedure
8.1 Test of Valves
(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.
8.2 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:
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 14 of 40
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 15 of 40
9) 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 19 of 40
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 Scope
Boiler superheater system
(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.
(6) 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:
Design value Actual setting value
Name/Type Popping Return Pressure Popping Pressure Return Pressure Remarks
Pressure(MPa) (MPa) (MPa) (MPa)
Drum
Safety valve 1.43 1.33-1.37 4-7%
A48Y-25
Super heater
Safety valve 1.30 1.21-1.25 4-7%
SA48Y-25
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 25 of 40
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.
3) Ignition of boiler.
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.
4) 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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 27 of 40
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.
Automatic adjustment of drum level
Automatic adjustment of furnace pressure
Automatic adjustment of combustion
Automatic adjustment of desuperheating water
(3) 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 28 of 40
9. Safety Measures
9.1 Safety rules for commissioning
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 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.
9.1.4 All professional staffs shall be on respective duties during the whole commissioning to
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 29 of 40
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 31 of 40
Verifie Rem
No. Items Requirements Result
d by arks
1 Conditions for trial commissioning
Boiler air pressure test has been successfully
□Yes □No
completed. Each air leakage has been treated.
Boiler proper and flue gas duct have been
□Yes □No
assembled and insulated.
Flue gas &air
(1) systems Individual commissioning and subsystem
commissioning of forced draft fans have been
completed. □Yes □No
instrument
and record
lists
(7) Instrument on site
control,
electric and □Yes □No
engineering
personnel
56
hot flushing
52
48
44
40
36
Pressure boosting curve-boiling out
32
28
24
20
16
12
8
Pressure(MPa)
1 1 1 0 0 0 0 0 0 0. 0. 0
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 38 of 40
To atmosphere
Target board
superheater
Upper drum
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning Procedure
SCCTI-TS-GL-CS-006-2009A Page 39 of 40
Desuperheatering water
adjustable valve
#1 oil return adjustable
valve
#2 oil return adjustable
valve
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) 0702-00-M-01-HLB-002
DWG No.
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
Table of Contents
1. PURPOSE ........................................................................................................................................... 3
2. SCOPE ................................................................................................................................................ 3
9. SAFETY MEASURES..................................................................................................................... 13
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 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 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
5.3 Tachometer;
5.4 Clip-on ammeter.
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
◆ 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;
8. Commissioning Procedure
8.1 Cold check and transmission test of damper baffle
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Forced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-007-2009A Page 7 of 24
8.3.2.2 Interlock test for the outlet damper and moving blade of FDF
8.3.2.2 Interlock test for the outlet interconnection damper of the FDF
9. Safety Measures
9.1 Safety rules for commissioning
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 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.
9.1.4 All professional staffs shall be on respective duties during the whole commissioning to
guarantee the safe operation of equipments.
9.2 Personal Risk and Preventative Measures
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Forced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-007-2009A Page 14 of 24
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 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Forced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-007-2009A Page 15 of 24
Verifie Remar
No. Items Requirements Result
d by ks
1. Environmental condition
Sites, roads and
(1) Flat, clear, clean □Yes □No
surroundings
Platform, staircase, rail, Complete
(2) guard board, and scaffold □Yes □No
for construction Demolished
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-EBC-001
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
SiChuan Electric Power Project
Commissioning & Test Institute
Approval Check
Design Procedure of Pulverizing System
Review
Date Scale REV
N/A DWG No.
SCCTI-TS-GL-CS-008-2009A A
PLTU 1 Jatim-Pacitan(2×315MW) Project
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................................................................... 5
6. PREREQUISITE FOR COMMISSIONING ............................................................................... 5
7. MEASURES FOR COMMISSIONING ORGANIZATION ....................................................... 6
8. COMMISSIONING PROCEDURE ............................................................................................ 8
9. SAFETY MEASURES .............................................................................................................. 23
9.1 Safety Rules for Commissioning...................................................................... 23
9.2 Personal Risk and Preventative Measures........................................................ 23
9.3 Equipment Risk and Preventative Measures .................................................... 24
9.4 Safety Precautions ............................................................................................ 24
10. APPENDIX................................................................................................................................ 25
10.1 Appendix 1 Commissioning Condition Checklist............................................ 25
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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 To check equipment running, verify system performance, and detect and remove any potential
defects.
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. Brief Description of System and Equipment
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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
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
4.2.2 Motor of coal mill
Model YMKQ500—6.6
Power kW 450
Voltage V 6600
Motor of Rated current A
coal mill
Rotation speed r/min 990
Power consumption at 100﹪ output of coal mill kWh/t 6-10
Insulation class F
4.2.3 Gear reducer of coal mill
Model MLX60-C1
Voltage V 380
Q'ty Heaters / mill 5
Model No. XYC001-000
Filter
Filter rating Μm 25
Model No. 2LAFW-F10
Cooling area m2 16
Cooler
Oil side pressure MPa 1.2
Water side pressure MPa 0.8
4.2.4 Coal feeder and technical specifications
Electronic
Type Model No. GM-BSC22
weighing type
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 Conditions that must be available for machinery provisions
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 Conditions that must be available for electrical and I&C
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
8. Commissioning Procedure
8.1 Cold check and transmission test of damper baffle
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.
(1) No MFT
Primary air permitting (any one of primary air fan
(2)
working and air pressure normal )
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 Fixed value Results Remarks
(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.
(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 Fixed value Results Remarks
(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.
(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 Fixed value Results Remarks
(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
(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
PLTU 1 Jatim-Pacitan(2×315MW) Project
5) Coal layer E is permitted to be put into service if any of following conditions is satisfied.
No. Test item Fixed value Results Remarks
(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
(4) Boiler load>60%
8.2.2.3 Conditions required by starting mill set (following conditions shall be satisfied completely,
and Mill A, B, C, D and E are same).
NO. Test item Fixed value Results Remarks
Coal of corresponding layer (milling layer) permitted
(1)
to be put into service.
(2) 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
(3)
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
(4)
non-extension end normal (<90℃)
(5) Cold air damper opened; hot air damper opened.
Differential pressure between upper and lower side of
(6)
mill bowl not high.
Differential pressure between primary air and seal air 2kPa
(7)
of mill not low; seal air damper opened.
(8) No coal mill in start-up procedure
(9) Outlet valve 3/4 opened of mill
Coal air mixture temperature normal at mill outlet
(10)
(65℃≤T≤85℃)
(11) Primary air flow ≥50T/H
Inlet valve opened and outlet valve closed at pebble
(12)
coal hopper of mill
PLTU 1 Jatim-Pacitan(2×315MW) Project
8.2.2.4 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.)
No. Test item Fixed value Results Remarks
Primary air fans stop if any one of mills runs (time
(1)
delayed for 2s)
Any three outlet valves are closed during mill
(2)
operating. (3 out 4 logic)
(3) Send out signal to actively stop mill from CRT.
(4) Coal feeder trips, time delayed for 15 min.
Flame-out: after coal feeder runs 2 min, any three
(5) coal burners at corresponding layer detect flame-out
(3 out 4 logic), or any three scanners fail.
(6) Mill primary air flow ≤35t/h (time delayed for 5S)
(7) MFT actuated.
(8) Local emergency button actuated.
Coal air mixture temperature at mill outlet ≥100℃
(9)
(time delayed for 2s) 2 out 3 logic.
Differential pressure between mill seal air and
(10) 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
(11) 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
(12)
end of mill: 95℃ (time delayed for 2s).
High-high bearing temperature at shaft extension end
(13)
of mill: 95℃ (2 out of 6 logic) (time delayed for 2s).
High-high temperature of motor winding of mill:
(14)
145℃(time delayed for 2s)
High-high vibration in direction X and Y of mill: time
(15)
delayed for 10s.
Bearing temperature of epicyclic gearbox of mill
(16)
>80℃ (2 out 4 logic), time delayed for 3s
Input bearing temperature of gear box of mill >90℃
(17)
(1 out 2), time delayed for 3s
8.2.2.5 Following valves are interlock-closed when mill trips (Mill A, B, C, D and E are same).
No. Test item Fixed value Results Remarks
(1) Fast swinging damper at cold air inlet of mill
(2) Fast swinging damper of hot air of mill
(3) Outlet vale of mill
PLTU 1 Jatim-Pacitan(2×315MW) Project
8.2.2.8 Conditions at which start-up of coal feeder is permitted (following conditions shall be
satisfied completely. A, B, C, D and E are same).
No. Test item Fixed value Results Remarks
PLTU 1 Jatim-Pacitan(2×315MW) Project
8.2.2.9 Interlock trip condition of feeder (feeder will trip if any of following conditions is satisfied. A,
B, C, D and E are same)
No. 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 Following valves are interlock-closed when feeder trips (Feeder A, B, C, D and E are same).
No. 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 Interlock test of dampers of pulverizing system (Mill A, B, C, D and E are same.)
Fixed Resu Rem
No. Test item
value lts arks
(1) Pulverized coal damper at burner inlet
Protection interlock-closing condition: Coal mill stopped (time delayed for
1)
3s), interlock closing.
(2) Motorized valve of fire smotherring steam of mill
1) Permissive opening conditions: Any one of seal air fans is running.
Protection interlock opening conditions: Coal air mixture temperature at mill
2) 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
3)
opened for 10 min and coal air mixture temperature at mill outlet lower than
PLTU 1 Jatim-Pacitan(2×315MW) Project
8.2.2.12 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
motor is qualified;
(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.
8.3.2 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:
PLTU 1 Jatim-Pacitan(2×315MW) Project
(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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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 Safety Rules for Commissioning
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 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.
9.1.4 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 Personal Risk and Preventative Measures
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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 Equipment Risk and Preventative Measures
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
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 Appendix 1 Commissioning Condition Checklist
No. Items Requirements Result Verified by Remarks
Environmental
1.
Conditions
Field, passage,
(1) Level, clear and clean □Yes □No
surroundings
PLTU 1 Jatim-Pacitan(2×315MW) Project
Documents, tools,
instruments, gauges and
(5) In readiness □Yes □No
sheets required by
commissioning
Personnel for inspection Adequately staffed and
(6) □Yes □No
and maintenance well-trained
(7) Measures disclosure Fulfilled □Yes □No
X0HFF32AA001
Outlet damper of mill C to corner 2
Local Remote Operating time
KKS code Name position On Date Result Signature Remarks
Direction Feedback Off(Close)
indication (Opening)
X0HFF33AA001 Outlet damper of mill C to corner 3
X0HFF34AA001
Outlet damper of mill C to corner 4
X0HFF42AA001
Outlet damper of mill D to corner 2
X0HFF43AA001
Outlet damper of mill D to corner 3
X0HFF51AA001
Outlet damper of mill E to corner 1
X0HFF52AA001 Outlet damper of mill E to corner 2
X0HFF53AA001 Outlet damper of mill E to corner 3
X0HFF54AA001 Outlet damper of mill E to corner 4
1#Corner A Layer Burner Inlet Pulverized
X0HFF11AA002
Coal Damper
1#Corner B Layer Burner Inlet Pulverized
X0HFF21AA002
Coal Damper
1#Corner C Layer Burner Inlet Pulverized
X0HFF31AA002
Coal Damper
1#Corner D Layer Burner Inlet Pulverized
X0HFF41AA002
Coal Damper
1#Corner E Layer Burner Inlet Pulverized
X0HFF51AA002
Coal Damper
X0LBX70AA002
Fire prevention steam valve of mill B
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HL-001
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check Procedure of Cold Ventilation and Air
Review Design
Measurement
Date Scale N/A DWG No. SCCTI-TS-GL-CS-009-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-009-2009A Page 2 of 24
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................................................................. 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
10.1 Safety Rules ©for Commissioning................................................................... 11
10.2 Personal Risk and Preventative Measures........................................................ 11
10.3 Equipment Risk and Preventative Measures .................................................... 12
11. 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-009-2009A Page 3 of 24
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
◆ Be responsible for machining of measuring holes for test and setup of test platform;
◆ 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-009-2009A Page 6 of 24
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning;
◆ Participate in and witness the commissioning work;
9. Commissioning Procedure
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-009-2009A 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.
9.2 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) Program startup of the forced draft fan on side of A and B
(5) Program startup of the forced draft fan on side of A and B
9.3 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:
Secondary airflow on A
A side B side A side B side A side B side
side (computer)
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
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Procedure
SCCTI-TS-GL-CS-009-2009A Page 9 of 24
Secondary airflow on A
side (actual measuring )
Secondary airflow on B
side (computer)
Secondary airflow on B
side (actual measuring )
(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.
9.6 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Procedure
SCCTI-TS-GL-CS-009-2009A Page 10 of 24
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:
Location of measuring
points Mill A Mill B Mill C Mill D Mill E
Coefficients
Coefficients of working
condition I
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Procedure
SCCTI-TS-GL-CS-009-2009A Page 11 of 24
Coefficients of working
condition II
Coefficients of working
condition III
Average coefficients
9.7 Cold state inspection and oscillation test for the burner
9.7.1 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.
9.7.2 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.
11. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
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Procedure
SCCTI-TS-GL-CS-009-2009A Page 13 of 24
Remar
No. Items Requirements Result Verified by
ks
Installation are completed and
1 System installation □Yes □No
records are complete
Operators in the main
The allocation is complete and
2 position and the □Yes □No
the training is qualified;
auxiliary position
Identification of The identification is complete
3 □Yes □No
equipment and correct.
Clear road, sufficiency of
4 Field condition □Yes □No
illumination
Communication
5 Sufficient and usable □Yes □No
equipment
6 Electric motor Correct wiring and earthing □Yes □No
The installation check is
I&C and electrical
7 completed, the commissioning □Yes □No
gage
can be made
The commissioning for the
individual equipment and
8 Air preheating system □Yes □No
system is completed, the
commissioning can be made
The commissioning for the
individual equipment and
9 All fan systems □Yes □No
system is completed, the
commissioning can be made
Providing with the operation
10 DCS system □Yes □No
conditions on CRT
The installation is completed
11 Coal mill system and the ventilation condition is □Yes □No
provided.
The inspection is completed,
12 Related damper □Yes □No
the commissioning is normal.
The fabrication and installation
Measuring holes for
13 are completed and the location □Yes □No
test
is correct.
The setting up is completed
14 Test platform □Yes □No
safely and reliably.
All the air flues for
The installation is completed
15 the flue-gas and air □Yes □No
and the inner is cleared cleanly.
system
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
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Procedure
SCCTI-TS-GL-CS-009-2009A Page 14 of 24
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
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
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Procedure
SCCTI-TS-GL-CS-009-2009A Page 16 of 24
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
air flue)
3000mm (distance between the inner wall of
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
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Procedure
SCCTI-TS-GL-CS-009-2009A Page 17 of 24
Appendix 3 Installation schematic diagram for the calibrated (checking) measuring points of primary
leveling and testing hole device at outlet of mill
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.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-009-2009A Page 18 of 24
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
No. Remarks
1 (in/out) point 2 (in/out) point 3 (in/out) 4 (in/out) 5 (in/out) 6 (in/out) ed by:
#1 primary air duct
#2 primary air duct
Coal mill A
#3 primary air duct
#4 primary air duct
#1 primary air duct
#2 primary air duct
Coal mill B
#3 primary air duct
#4 primary air duct
#1 primary air duct
#2 primary air duct
Coal mill C
#3 primary air duct
#4 primary air duct
#1 primary air duct
#2 primary air duct
Coal mill D
#3 primary air duct
#4 primary air duct
#1 primary air duct
#2 primary air duct
Coal mill E
#3 primary air duct
#4 primary air duct
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
Commissioning Procedure
SCCTI-TS-GL-CS-009-2009A Page 20 of 24
Measuring point Measuring point Measuring point 3 Measuring point Measuring point Measuring point Confirm Remar
No.
1 (in/out) 2 (in/out) (in/out) 4 (in/out) 5 (in/out) 6 (in/out) ed by: ks
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
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)
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Cold Ventilation and Air Measurement REV A
Commissioning Procedure
SCCTI-TS-GL-CS-009-2009A Page 23 of 24
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) 0702-00-M-01-GCC-001
DWG No.
PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN
Commissioning & Test Institute Project STAGE
Approval Check
Review Design Procedure of Air Compressor System
Scale DWG REV
Date N/A No.
SCCTI-TS-GL-CS-010-2009A A
Table of Contents
1. PURPOSE .................................................................................................................................... 3
2. SCOPE ......................................................................................................................................... 3
3. PREPARATION BASIS............................................................................................................... 3
10. APPENDIX................................................................................................................................ 11
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.
8. Commissioning Procedure
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.
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 Safety Rules for Commissioning
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 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.
9.1.4 All professional staffs shall be on respective duties during the whole commissioning to
guarantee the safe operation of equipments.
9.2 Personal Risk and Preventative Measures
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 Equipment Risk and Preventative Measures
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 Appendix 1 Commissioning Condition Checklist
Verified Rem
No. Items Requirements Result
by arks
Installation over, record
1 Installation of system □Yes □No
complete
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
Passage clear, adequate
5 Field condition lighting, emergency lighting □Yes □No
available
6 Communication device Available □Yes □No
Adequate and easily
7 Fire apparatus □Yes □No
accessible
8 Overhaul tools and materials Complete and adequate □Yes □No
Tools for running, record
9 Prepared □Yes □No
sheet
Tools, instruments and
10 apparatuses for Prepared □Yes □No
commissioning
11 Electrical connection Secure and reliable □Yes □No
12 Oil separator Oil level appropriate □Yes □No
13 Cooling water system Clear and free of leakage □Yes □No
14 Vent valve Operated freely □Yes □No
15 Gauges and meters Complete and verified □Yes □No
Owner: Date:
10.2 Appendix 2 Instrument Air Compressor Valve Record
Instrument Air Compressor Valve Record
Owner: Date:
PLTU 1 Jatim-Pacitan (2×315MW) Project
Commissioning Procedure
Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-EG-001
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) DESIGN
& Test Institute Project STAGE
Approval Check
Design Procedure of Fuel Oil System
Review
DWG REV
Date Scale N/A No.
SCCTI-TS-GL-CS-011-2009A A
PLTU 1 Jatim-Pacitan(2×315MW) Project
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........................................................... 3
6. PREREQUISITE FOR COMMISSIONING ............................................................................... 4
7. MEASURES FOR COMMISSIONING ORGANIZATION ....................................................... 5
8. COMMISSIONING PROCEDURE ............................................................................................ 6
9. SAFETY MEASURES .............................................................................................................. 17
9.1 Safety Rules for Commissioning........................................................................................ 17
9.2 Personal Risk and Preventative Measures.......................................................................... 17
9.3 Equipment Risk and Preventative Measures ...................................................................... 17
10. 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
1. 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. Tools and Instrument for Commissioning
5.1 Walkie talkie;
5.2 Vibration measurement instrument;
PLTU 1 Jatim-Pacitan(2×315MW) Project
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. 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
PLTU 1 Jatim-Pacitan(2×315MW) Project
8. Commissioning Procedure
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 Interlock test for fuel oil system before boiler
Sr.N
Test item Fixed value Results Remarks
o.
PLTU 1 Jatim-Pacitan(2×315MW) Project
(2)
Conditions for open interlock: (the valve opening by
interlock under any conditions as below)
Oil leakage test to open oil feed rapid close valve
8.2.3 Interlock Protection Test for Fuel Oil Pump House System
Sr.No. Test item Fixed value Results Remarks
1. Startup conditions for oil unloading pump A
PLTU 1 Jatim-Pacitan(2×315MW) Project
(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.
8.7 Fuel oil leakage test
Coordinate with I&C to complete the leakage test prior to ignition:
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
(6) 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
AB-1
AB-2
AB-3
AB-4
BC-1
BC-2
BC-3
BC-4
DE-1
DE-2
DE-3
DE-4
AB1/3
PLTU 1 Jatim-Pacitan(2×315MW) Project
AB2/4
BC1/3
BC2/4
DE1/3
DE2/4
AB
BC
DE
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 Safety Rules for Commissioning
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 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 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 Equipment Risk and Preventative Measures
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
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
PLTU 1 Jatim-Pacitan(2×315MW) Project
Completed, error
(1) System inspection □Yes □No
correction completed
Operators deployed,
(2) Production preparation operation tools ready and □Yes □No
operation log ready
Storage adequate and
(3) Fuel oil quality of oil conforming □Yes □No
to design
Overhaul tools and
(4) Complete □Yes □No
materials
Commanding organization Established and work
(5) □Yes □No
system division clear
Commissioning materials,
(6) tools, instruments, meters Ready and complete □Yes □No
and record formats
(7) Maintenance personnel Sufficient; training passed □Yes □No
(8) Clarification for methods Fulfilled □Yes □No
AB1
AB2
AB3
AB4
BC1
BC2
BC3
BC4
DE1
DE2
DE3
DE4