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PAF
and
System
Commissioning Procedure
Compiled by:
Reviewed by:
Approved by:
2014
Catalogue
1. OVERVIEW ...................................................................................3
2. MAIN EQUIPMENT TECHNIQUE
SPECIFICATION.......................................................................................3
3. COMMISSIONING BASIS AND STANDARD .....7
4. COMMISSIONING PURPOSE ...........................................8
5. COMMISSIONING CONDITION..................8
6. COMMISSIONING PROCESS AND
METHOD.....................................................................................................8
7. COMMISSIONING INSTRUMENT AND
EQUIPMENT............................................................................................11
8. COMMISSIONING QUALITY AND
ASSESSMENT STANDARD....................................................................11
9. ENVIRONMENT,
OCCUPATIONAL HEALTH AND SAFETY CONTROL
PROCEDURE............................................................................................12
10 ORGANIZATION AND DIVISION..............................12
11. APPENDIX..................................................................................15
2
Boiler PAF and System Commissioning Procedure
1.
Overview
ZMTP 2150MW
2510t/h
The project is Zambia ZMTP 2150MW coal fired power plant, located at
Maamba coal mine, Sinazongwe, Southern Province. The boiler is produced by
Dongfang Boiler Company, which is 2*510t/h high temperature, super high pressure
circulating CFB boiler. Here the procedure is for the boiler PAF and system
commissioning.
Each boiler is matched with two sets of centrifugal IDF, controlled by damper
and hydraulic coupling; two sets of centrifugal PAF, controlled by damper and
hydraulic coupling; two sets of centrifugal FDF; controlled by damper and hydraulic
coupling; three sets of HP fluidized blower, controlled by motor butterfly damper and
hydraulic coupling, which are all produced by Shanghai Blower Works Company.
2.
2.1
Boiler specification
Zambia MCL 2150MW Coal Fired Power Plant 2 510t/h
150MW
Zambia MCL 2150MW Coal Fired Power Plant is provided with two sets of
510t/h super high pressure, natural circulating CFB steam drum boilers, which is
single furnace, single medium reheating, thermal isolation cyclone separator, tubetype air preheater, balanced draft, end part double flue, suspension structure, halfunsheltered layout, solid state deslagging, complete steel structure, matched with
150MW condense turbine-generator. The boiler adopts CFB combustion and
limestone desulfurization technique that low pollution and high efficiency.
Item
Unit
T/H
BMCR
BECR
510
485.73
MPa
14.32
14.32
540
540
LP RH inlet pressure
LP RH inlet temp.
HP RH inlet pressure
HP RH inlet temp.
RH flow
Feed
water
temp.
exclusive all HP
#1
Feed
water
temp.
exclusive #1 HP
#2
Feed
water
temp.
exclusive #2 HP
(LHV)
Boiler
guaranteed
efficiency (LHV)
Boiler
desulfurization
efficiency
MPa
2.85
2.85
334
334
MPa
2.7
2.7
540
540
T/H
420.42
400.4
248
248
171
228.6
207.3
90
92.3
2.2
Fan technique parameter
FDF system mainly comprises following equipment: two SAFs, two SAF
motors, two hydraulic couplings, two sets of auxiliary equipment of hydraulic
coupling, control and protection.
5
PAF mode and type
Mode: centrifugal
2378AB/1160
Type: 2378AB/1160
STMKK500-4L-TH
The fan is mainly composed of shell, admission box, air inlet, transmission
mechanism, blade wheel, bearing, control mechanism, etc. The fan is linked by
junction box and hydraulic coupling, driven by motor, which the type is STMKK5004L-TH,
1
Sheet 1: PAF design parameter:
Performance
SAF flow
point
Inlet negative Full
Inlet
temp.
pressure
load
pressure rising
TB
Nm3/h
Pa
Pa
215850
40
-350
26830
179875
20
-350
18632
T, B point
BMCR
Design (BMCR)
2
Sheet 2: PAF regulation
No.
Item
1
2378AB/1160
Mode
85.5
85.5
kg/h
243484
TB
Selec
8
ted
232776
26906
40
working
kW
condition
TB
10
kg/h
202824
181584
18332
20
working
1011.2
condition
11
12
BMCR
Calculat
13
ed
14
1849.6
(BMCR
)
15
Q235A
16
Shell material
mm
10
17
45#
18
Shaft material
/
15MnV
19
10
20
3.5
21
18
22
Bearing mode
Rolling
bearing
8
23
Open
24
m /h
cooling
9000
25
200
26
Manufacturer
Xiangtan
27
water
Motor
YKK630-4
Type
kW
2050
29
6600
30
Voltage (V)
r/min
1480
31
IP55
32
Protection grade
33
Cooling code
Air-air cooling
34
Bearing mode
Sliding bearing
Neutral
Dalian
28
Driven motor
point
transformer
35
current
Zhongguang
+
Inlet
damper
hydraulic coupling
3
9
Name
Unit
Rated load
Max.
Design
value
KW
Output power
Slip
KW
Slip loss
KW
Fixed loss
KW
Input power
r/min
Input speed
r/min
Output speed
Rotation direction
Driving shaft
Driven shaft
Speed
control
range
Lube
oil
pump
10
Name
Unit
Rated load
Max.
Design
value
mode
Working
MPa.g
oil
pressure
l/min
MPa.g
l/min
Oil cooler
Design
pressure
MPa.g
of
MPa.g
OC
Design temperature of
working oil cooler
OC
Design temperature of
lube oil cooler
m2
11
Name
Unit
Rated load
Max.
Design
value
Cooling
area
of
working oil
m2
Cooling water
t/h
MPa.g
t/h
MPa.g
Introduction:
1.TB(test block)
TB (test block): allowance shall be reserved for air flow and pressure in TB
working condition.
2.BMCR BMCR
BMCR: boiler maximum continuous rating. The fan parameter shall be
checked under BMCR working condition.
3.
Above air flow and pressure data has been modified to selected state.
4.
12
3.
3.1 DL/T5437-2009
Code for Fossil Power Construction Project from the Unit Commissioning to
Completed Acceptance by National Energy Administration DL/T5437-2009
3.2 DLT852-2004
Guide for Boiler Start-Up Commissioning Test by NDRC DLT852-2004
3.3 DL5009.1-2002
Code of Safety Operation in Power Engineering Construction Part 1:
Steam Power Plants by Electric Power Industry Standard
3.4 DLT
5210.2-2009
Code for Construction Quality Acceptance and Evaluation of Electric Power
Construct. Part 2: Boiler Unit by National Energy Administration DLT 5210.2-2009
3.5 1996
Standard for Quality Inspection and Evaluation on the Commissioning of
Thermal Power Plant (1996 version)
3.6 1996
Regulations on the Start-up commissioning of Thermal Power Plant Projects
(1996 version)
3.7 [2002]49
Power Construction Safety and Health and Environmental Management
Regulations, State Grid Corporation [2002]49
3.8
Relevant contracts, design drawings, manufacture introduction, technique
agreement and other documents.
3.9 MCL 2150MW
3.10
4.
Commissioning purpose
4.1
In order to guide and regulate system and equipment commissioning, and put into
operation safely and normally, hereby the procedure is compiled.
4.2
Check electric and I&C protections interlock and signal devices, and confirm the
action reliability.
4.3
Check equipment operation and systems performance, find and remove the possible
problems.
5.
Commissioning condition
1
6.
14
PAF system commissioning work can be carried out as per following flow chart:
Technique handover
Condition confirm
completed.
Safety condition are satisfied.
15
Interlock protection
Alarm test
alarm test
6.1
Actuator check
6.1.1
Check and accept motor air valve dampers, record data;
6.1.2
Check and accept motor control air valves, record data.
16
6.2
Thermal signal check
6.2.1
Check and accept analog and switching value signal, record data.
6.2.2
For above signal, on site position shall be considered to analyze the reality of
collected signal, if not, response and suggest to construction unit.
6.2.3
Air fan emergency button test.
The air fan emergency button erection and wire connection shall be complete
and correct, and the emergency button simulation test can make air fan trip.C
6.3
Interlock protection and alarm signal check
6.3.1
6.3.3
6.3.4
6.3.4.1
a)
Covers for ditch and channel shall be complete; stairs, path way and guard rail
shall be complete; all sundries shall be cleaned up.
b)
Communication system commissioning shall be completed and qualified.
c)
Industrial and emergency illumination shall be complete and sufficient.
d)
Confirm that PAF and its system erection are completed.
e)
Air channel of PAF shall be cleaned up without any foreign materials that may
cause air fan damage.
f)
Manholes of PAF outlet air channel and body shall be closed and accepted.
g)
Air valves and dampers shall be checked and qualified.
h)
I&C erection and verification shall be qualified.
i)
k)
18
PAF and its system commissioning is completed and qualified, which can be
put into operation.
m)
Manual turning PAF and its rotor shall be normal.
n)
FDF and its motor single commissioning are completed, junction box of motor
and SAF is reset completely.
o)
FDF and its motor bearings are provided with lube oil sufficiently.
p)
Insulation resistance of the motor shall be measured and qualified.
6.3.4.2
Protection or interlock that does not affect safety shall be cut off and recorded.
6.3.4.3
PAF startup preparation
a)
Carry out check as per auxiliary code before startup, which shall be qualified.
b) CRT
Confirm that PAF inlet and outlet dampers shall work well, and local opening shall
be identical with CRT display.
c)
Confirm that PAF bearing is filled with qualified lube oil.
d)
Put cooling water system into operation to observe water flow, which shall be
normal.
e)
PAF has been started.
19
f)
DCS
If no abnormal situation, restart PAF after 30 minutes, then gradually control
parameter of PAF control damper and hydraulic coupling, supervise PAF current to
prevent overcurrent operation. Record all operation parameter (local and DCS data
shall be recorded separately).
6.3.4.6
Operation parameter shall be supervised during operation, which shall be in normal
range.
6.3.4.7
Check the system leakage and air channel vibration.
6.3.4.8 8
20
PAF and its system commissioning shall be kept for 8 hours, then shutdown the PAF
and record the idle hour.
6.3.4.9
After PAF shutdown, cut off PAF power.
6.3.4.10
The air channel shall be freely flowing to prevent vibration caused by air valve
misoperation closing.
6.3.4
a)
72
The system reliability shall be checked as per no load stage, on-load stage, full
load stage and 168 hours operation.
b)
The system dynamic control, including primary air flow and pressure control.
c)
The equipment supervision shall be enforced during system operation,
especially during furnace negative pressure control to ensure that the system in
optimal operation condition.
d)
Fill in commissioning record.
7.
Vibration gauge
21
Revolution meter
Clip-on ammeter
Phonometer
8.
The air fan operation shall be stable and normal; bearing bush temperature and
vibration, cooling water system and motor coil temperature are normal.
8.3
Professional commissioning staff and supervisor shall strictly check and control the
22
important process of commissioning quality, and report to higher level leader when
find out any problems to solve it under coordination to guarantee operation
successfully.
9.
When PAF and its system first startup, relevant staff shall be on equipment site
to supervise strictly with reliable communication to control room.
9.2 ,
When PAF test running, startup time and current shall be supervised strictly,
instantly shutdown if startup current is too long or current fluctuates rapidly.
9.3
On-site safety regulation shall be carried out strictly by all commissioning staff to
23
9.9 Safety helmet shall be worn during on-site commissioning, and possible danger
work shall be analyzed by person in charge on site and eliminate hidden danger.
All commissioning staff shall strictly carry out on-site safety regulation to
guarantee safety and reliability.
10
10.1
Erection unit
10.1.1
In charge of organization of subsystem commissioning.
10.1.2
In charge of the system isolation and closing.
10.1.3
In charge of maintenance, overhaul and troubleshooting of commissioning equipment.
24
10.1.4
Prepare necessary overhaul tools and material.
10.1.5
Coordinate with the commissioning unit to carry out subsystem commissioning.
10.1.6
In charge of temporary mark on relevant system and equipment.
10.1.7
In charge of check and acceptance after subsystem commissioning.
10.2
Construction unit
10.2.1
In charge of equipment startup, shutdown, operation control and accident elimination
during the commissioning.
10.2.2
In charge of formal mark for relevant systems and equipment.
10.2.3
Prepare operation regulation, tools and record sheet.
10.2.4
In charge of inspection and normal maintenance for commissioning equipment.
10.3
Commissioning unit
10.3.1
In charge of compiling commissioning procedure and technique handover.
10.3.2
Prepare relevant measuring instrument, apparatus and tools.
10.3.3
Engage in subsystem commissioning.
25
10.3.4
In charge of test data recording and filing.
10.3.5
Fill in inspection and qualification sheet of commissioning quality.
10.3.6
Engage in check and acceptance after subsystem commissioning.
10.3.7
In charge of compiling commissioning report.
10.4
10.4.1
In charge of supervisory work during starting and commissioning as per the contract,
supervise the procedure execution, engage in the commissioning, check and
acceptance.
10.5
26
11.
Appendix
1
Appendix 1: Checking list for PAF commissioning condition
No.
Checking content
Requirement
Date
Result
Rem
ark
1-1
No.
Checking content
Requirement
Date
Result
Rem
ark
1-2
Complete
PAF
and
air
channel
cleaning
1-3
Complete
PAF
and
air
channel
cleaning
1-4
Normal
bearings
1-5
2-1
2-2
2-3
Flexible
valves
correct direction.
Measuring meter
operation,
verification.
28
No.
Checking content
Requirement
Date
Result
Rem
ark
2-4
Test is qualified.
Electrical
and
protection,
interlock
I&C
and
signal device
2-5
Qualified
control
and
correct direction.
2-6
3-1
Power
Reliable
On-site road
sufficient
illumination
and
emergency illumination.
4-1
On-site
communication
equipment
4-2
4-3
Firefighting facilities
Sufficient
Maintenance
(including
staff
electrical
and
thermal staff)
29
No.
Checking content
Requirement
Date
Result
Rem
ark
4-4
Maintenance
tools
and
Enough
material
4-5
Operation
tools
and
Readied
recording sheet
4-6
Test
instrument
and
Readied
apparatus
Date:
30
2
Appendix 2: Commissioning record PAF system air valves
KKS
KKS No.
Name
Remote operation
Time
Local
S R
indication
i e
correct
Cl
Correct
Correct
pe
os
direction
response
C C g m
h h n a
e e a r
c c t k
k k u
i i r
XXXXXXX
A PAF outlet
damper
XXXXXXX
B PAF outlet
damper
XXXXXXX
A PAF inlet
damper
XXXXXXX
B PAF inlet
damper
31
XXXXXXX
X
XXXXXXX
X
XXXXXXX
X
XXXXXXX
X
3
Appendix 3: PAF system interlock protection test card
No.
Test content
PAF
30%
FDF is in operation condition, with air flow over 30%.
<5%
PAF frequency converter <5%
32
Result
Remark
No.
Test content
4
<5%
PAF inlet damper <5%
Interlock shutdown
MFT
MFT action
75
80
XY4.6mm/s
2S
If any PAF front and rear bearing vibration is over
4.6mm/s to X or Y direction, 2s time delay, (PAF protection
interlock into operation)
82TE-01174B~82TE01179B(62140)
145
PAF
motor
stator
coil
temperature
(82TE-
33
Result
Remark
No.
Test content
II
III
34
Result
Remark