Boiler Ash Removal System Commissioning Procedure

Compiled by:

Reviewed by:

Approved by:

2014

Qingdao

Huachen

Technology Engineering Co., Ltd.

Weiye

Electric

Power


Catalogue
1. overview ..........................................................................................................3
2. main equipment technique specification..............................3
3. commissioning basis and standard ..........................................7
4. commissioning purpose .........................................................................8
5. commissioning range..............................................................................8
6. commissioning condition and checking
content..........................................................................................................................8
7. commissioning process and method...........................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


Boiler Ash Removal 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 ash removal system
commissioning.

2.
Main equipment technique specification
2.1
Boiler specification
Zambia MCL 2150MW Coal Fired Power Plant 2 510t/h

150MW
3


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.

Boiler main parameter sheet

Item

Unit

BMCR

BECR

Main steam flow

T/H

510

485.73

Main steam pressure

MPa

14.32

14.32

Main steam temp.

540

540

LP RH inlet pressure

MPa

2.85

2.85

LP RH inlet temp.

334

334

HP RH inlet pressure

MPa

2.7

2.7

HP RH inlet temp.

540

540

RH flow

T/H

420.42

400.4

Feed water temp.

248

248

Feed water temp. exclusive

all HP

171

#1
Feed water temp. exclusive
#1 HP

228.6

#2
Feed water temp. exclusive

207.3

#2 HP
(LHV)
Boiler guaranteed efficiency
(LHV)

90

Boiler
desulfurization
efficiency

92.3

Coal quality analysis:

Description

Range of Coal
Analysis

Coal Analysis
Performance
Worst

ProximateAnalysis(ADB)
Ash

45.3 to 53.27

48.3

53.27

Volatile Matter (ADB)

Fixed Carbon (ADB)

%
%

19.6 to 18.05
33.7 to 27.47

18.8
31.55

18.08
27.44

Inherent Moisture (ADB)

Total Moisture

%
%

1.35
1.9

1.21
2.1

1.4 to 1.21
1.9 to 2.1

Normal Heating Value

Kcal/kg
UltimateAnalysis(as received basis)

4059 to 2990

3500

3110

Carbon (C)
Hydrogen (H2 )

%
%n

42.8 to 37.06
2.81 to 2.33

37.5
2.45

33.26
2.33

Nitrogen (N2)
Oxygen (O2)

%
%

0.93 to 0.72
6.45 to 6.08

0.85
6.20

0.72
6.34

Sulphur (S)
Moisture (H2O)

%
%

1.0 to 2.0
1.43 to 1.24

1.7*
1.90

1.7*
2.1

%
Kcal

45.3 to 53.25
4039 to 3191

49.4
3580

53.55
3191

Hard grove index

Ash Analysis

HGI

59

59

59

Silica (SiO2)
Alumina (A12O3 )

%
%

61.08
30.52

61.13
30.89

Iron Oxide (Fe2O3)

Titanio (TiO2)

%
%

4.8 to 3.63
3.00 to 3.44

4.10
3.1

3.63
3.44

Phosphoric Anhydride(P2O5)

0.50 to 0.37

0.43

0.37

Ash
Gross calorific value (as received
basis)

/kg

61.7 to 61.13
31.0. to 30.89

2.2
5

Ash removal system regulation and main equipment technique data

2.2.1
Ash removal system regulation:

MCR 230%
1
Ash removal system adopts positive pneumatic dense phase ash conveying
system, which the conveying capacity is not less than 230% ash discharging quantity
under MCR working condition. Dust precipitator is single channel ESP, each hopper
of precipitator and APH is provided with one set of pneumatic pump.

2 7 14
2

2120m3 31.8m
Precipitator hopper is provided with gasification air system, matching with
gasification air fan, electric heater and hopper gasification plate. 2 public ash silos are
matched for two boilers, and each boiler is provided with 7 ash pipes, total 14 for two
boilers. Each ash pipe can be converted between two ash silos through change-over
valves on silo top. The design can satisfy two boilers operation simultaneously, or
single boiler operation, and two boilers ash removal systems will not affect each other
and guarantee the output. Volume of reinforced concrete ash silo is 2120m 3, with top
height of 31.8m.

~25%

Gasification device is installed at bottom of ash silo, and ash removal box,
6

exhaust filter (bag dust collector), pressure vacuum release valve, level gauge and
other equipment are installed on ash silo top. Two ash removal mode are used under
each ash silo with three dumping outlets, in which the first outlet to discharge dry ash
to tank truck to outside users; the second to discharge dry ash to humidification mixer
to produce wet ash with 25% water content, which is also used by outside user; the
third is standby.
1
234

Pneumatic ash removal system including following sub-system: (1) precipitator

(including APH) fly ash conveying system; (2) control air usage system; (3) system of
top discharging, exhaust and level indication; (4) control system of pneumatic system.
2.2.1.1
Precipitator fly ash conveying system
()

Precipitator fly ash conveying system (including APH) is designed as one boiler
as a unit, from under outlet flange of precipitator and APH hopper to inlet flange of
silo top discharging box, including silo and pump assembly (pressure conveying
device), pneumatic conveying pipe, pipe change-over valves, pipe expansion joints,
pipe blowing devices, etc.
2.2.1.2
Control air usage and bag pulse cleaning air usage system

Used air by pneumatic elements and bag pulse cleaning of top exhaust filter is from
compressed air center of the plant for instrument system.
2.2.1.3
System of silo discharging, exhaust and level indication
7

Including silo top discharging box, silo top exhaust filter (bag dust collector), pressure
vacuum releasing valve, silo top pipe change-over valves, level gauge and other
equipment and accessories.
2.2.1.4 PLC
Control system of pneumatic ash removal system (except PLC control cabinet)

All magnetic valves box and monitoring instrument required by the entire pneumatic
ash removal control system. All equipment can be controlled locally by auto and
manual, also controlled in control room by remote, and local control can lock the
other control modes.

Ash and slag quantity

Coal category

Unit capacity
(t/h)

(t/h)
Ash quantity per hour

Ash
Slag

slag

Ash and

Design coal

1150

44.02

44.02

88.04

2150

88.04

88.04

176.08

Checking coal

1150

53.59

53.59

107.18

2150

107.18

107.18

214.36

1. 50% 50%
Note: slag quantity is calculated as per proportion of 50% of total ash and slag,
as well as ash.
2. q4 4.27%
Mechanical imperfect combustion loss: q4 4.27%
3. 3%
Sulfur ARB: 3%

Ash quantity of single boiler with two precipitators

Discharging point

Hopper
quantity

Precipitator
electric field

Precipitator
electric field

Precipitator
electric field

Precipitator
electric field

Precipitator
electric field

Precipitator
electric field

APH hopper

22

Ash quantity of each Ash quantity of each

hopper by design coal
hopper by checking
coal
6.47 4=25.88
9.266 4=37.064

22

1.731 4=6.924

2.48 4=9.92

22

0.4556 4=1.822

0.6525 4=261

22

0.2734 4=1.0936

0.3915 4=1.566

22

0.1367 4=0.5468

0.1958 4=0.7832

22

0.04556 4=0.1822

0.06525 4=0.261

0.911 4=3.644

1.305 4=5.22

II

III

IV

VI

2.2.2
Main equipment technique data of ash removal system

APH pressure conveying device

Type

Inlet diameter

Capacity per set

Outlet diameter

6.0E/8
DN200
0.20 M3
DN100

Silo and pump assembly height

Including compensator, rectangle-circle

connector, manual pneumatic valves
1.0 MPa

Design pressure
0.35 MPa

Working pressure

610 Kg
Device weight
6.003t/h

Output
400

Working temperature
0-380

Usage temperature range

Material
Ductile cast iron
0.58m/18mm
/
Transmitter inner diameter/wall thickness
18mm

Pump thickness

Manufacturer
Clyde

Pressure conveying device of electric field fly ash (filling for various fields)

Conveying pump
I field
II field
III field
IV field
V field
80/8
80/8
9/8
8.0/8
8.0/8

Type
DN200
DN200
DN200
DN200
DN200

Inlet diameter
2.50
2.50
0.33
0.30
0.30

Capacity per set
DN150
DN150
DN150
DN150
DN150

Outlet diameter
1.0MPa
1.0MPa
1.0MPa
1.0MPa
1.0MPa

0.35
0.35
0.35
0.35
0.35

Design pressure

750Kg 710Kg 710Kg

Device weight
1300Kg
1300Kg
85.24t/h
22.81t/h
6.003t/h
3.602t/h
1.801t/h

Output
150
150
150
150
150

Working temperature
10

VI field
8.0/8
DN200
0.30
DN150
1.0MPa
0.35
710Kg
0.6t/h
150

0
Usage temperature 150
range
16MnR

Material

Service life of pump

(pressurized
components)
(considering
abrasion)

Gasification
plate
material
of
transmitter

Gasification
plate
service
life
of
transmitter
/
Transmitter
inner
diameter/wall
thickness

Pump thickness

Manufacturer

Quantity

0150

0150

0150

0150

0150

16MnR

16MnR

30
30 years

30
30 years

30
30 years

Ductile
cast iron
30
30 years

Ductile
cast iron
30
30 years

Ductile
cast iron
30
30 years

No

No

No

No

No

No

No

No

No

No

No

No

8mm

8mm

6mm

15mm

15mm

15mm

8mm

8mm

6mm

15mm

15mm

15mm

Clyde
8

Clyde
8

Clyde
8

Clyde
8

Clyde
8

Clyde
8

120.06t/h
System output for each boiler: (system output: 120.06t/h)

85.24th

Hopper conveying pipe output of I field

22.81-85.24th

Hopper conveying pipe output of II field

6.003-22.81th

Hopper conveying pipe output of III field

11

3.602-6.003th

Hopper conveying pipe output of IV field

1.801-3.602th

Hopper conveying pipe output of V field

0.6003-2.401th

Hopper conveying pipe output of VI field

6.003th

Hopper conveying pipe output of APH

120.06t/h
Average proportion of conveying ash and air (system output: 120.06t/h)

39.7

kgkg

39.7

kgkg

31.7

kgkg

31.7

kgkg

31.7

kgkg

31.7

kgkg

30.1

kgkg

38.2

kgkg

Proportion of conveying ash and air of I

field

Proportion of conveying ash and air of II

field

Proportion of conveying ash and air of III

field

Proportion of conveying ash and air of IV

field

Proportion of conveying ash and air of V

field

Proportion of conveying ash and air of VI

field

Proportion of conveying ash and air of

APH field

12

Proportion of conveying ash and air of

each boiler

Expansion joint under hopper

I field

Mode and type

Quantity

Specification

Design pressure

Temperature tolerance

Material

II field

Fields of III, IV,

V and VI

No

APH

Flexible
joint
8

Flexible
joint
8

DN200

DN200

Normal
pressure
200

Normal
pressure
200

Stainless
steel
40mm

Stainless
stee
40mm

Compensation

Manufacturer
Clyde
Clyde

Transition rectangle-circle connector

I field
II field
8

Quantity
200x200
Specification
DN200
Q235

Material

Manufacturer
Clyde

Pneumatic dome valve

No

APH

200x200DN200
Q235

Fields of III, IV,

V and VI
8/
8 per field
200x200DN200
Q235

Clyde

Clyde

Clyde

13

4
200x200DN200
Q235

I field

II field

Mode and type Pneumatic

dome valve
DN200

Specification

Driving mode Pneumatic

Valve
body Ductile
cast
material
iron

Valve
plate Ductile
cast
material
iron

Seal
ring Special rubber
material
DN200

Seal ring type

Manufacturer Clyde
8

Quantity

APH

Pneumatic
dome valve
DN200

Fields of III,
IV, V and VI

Pneumatic
dome valve
DN200

Pneumatic

Ductile
cast
iron

Ductile
cast
iron

Special rubber

Pneumatic

Ductile
cast
iron

Ductile
cast
iron

Special rubber

Pneumatic

Ductile
cast
iron

Ductile
cast
iron

Special rubber

DN200

DN200

DN200

Clyde
8

Clyde
8/
8 per field

Clyde
4

Silo pump discharging valve

I field
II field

III field

Mode and type

No

No

No

Specification

Driving mode

Valve body material

Valve plate material

14

Pneumatic
dome valve
DN200

Fields of IV, V
and VI

Pneumatic dome
valve
DN150

APH

Pneumatic

Ductile cast iron

Ductile cast iron

No

Seal ring material

Special rubber
DN150

Seal ring type

Manufacturer
Clyde
6

Quantity

Pneumatic air admission valve, including silo pumps various valves and
components (including air admission components on main ash conveying pipe and
discharging pipe)

I field
II field
Fields of III, APH
IV, V and VI

Mode and type Pneumatic

Pneumatic
Pneumatic
Pneumatic
butterfly
butterfly
butterfly
butterfly
damper
damper
damper
damper
4
4
8
2

Quantity

Driving mode
Pneumatic
Pneumatic
Pneumatic
Pneumatic
DN65
DN65
DN50
DN50

Specification

Valve
body Cast steel
Cast steel
Cast steel
Cast steel
material

Valve
plate Cast steel
Cast steel
Cast steel
Cast steel
material

Seal
surface Hard seal
Hard seal
Hard seal
Hard seal
material

Manufacturer
Clyde
Clyde
Clyde
Clyde

Pneumatic exhaust valve, including various valves and components of silo pump
exhaust components, classified by use in different ESP and filled as per different pipe
diameter and pressure.

15

I field

II field

Fields of III, APH

IV, V and VI

dome No
No

Mode and type Pneumatic dome Pneumatic

valve
valve
8
8

Quantity

Driving mode Pneumatic

Pneumatic
DN80
DN80

Specification

Valve
body Ductile cast iron Ductile cast iron
material

Valve
plate Ductile cast iron Ductile cast iron
material

Seal
ring Special rubber
Special rubber
material
20000 20000

Service life of
valve
body
and plug

Manufacturer
Clyde
Clyde

Silo pump discharging pipe isolation valve

I field
II field III field Fields of, IV, V APH
and VI

Mode
and Damper Damper Damper Damper valve
Damper valve
type
valve
valve
valve
2
2
2
2/
2

Quantity
2 per field

Driving
Manual Manual Manual Manual
Manual
mode
DN150 DN150 DN150 DN150
DN125

Specification

16

Valve body Cast

material
iron

Valve plate Cast

material
iron
-Seal
ring
material

Manufacturer Clyde

Discharging valve

I field

Mode
and
type

Quantity

Driving
mode

Specification

Valve body
material

Valve plate
material

Seal surface
material

Seal
ring
material

Manufacturer

Cast
iron

Cast
iron
--

Cast
iron

Cast
iron
--

Cast iron

Cast iron

Cast iron

Cast iron

--

--

Clyde

Clyde

Clyde

Clyde

II field

III field

Ball valve

Ball valve

Ball valve

Fields of, IV, V APH

and VI

Ball valve
Ball valve

Pneumatic Pneumatic Pneumatic Pneumatic

Pneumatic

DN50

DN50

DN50

DN50

DN50

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Alloy
steel

No

Alloy
steel

No

Alloy
steel

No

Alloy steel

No

Alloy
steel

No

Clyde

Clyde

Clyde

Clyde

Clyde

3.

17

Commissioning basis and standard

3.1DL/T5437-2009
Code for Fossil Power Construction Project from the Unit Commissioning to
Completed Acceptance by National Energy Administration DL/T5437-2009
3.2DL/T5190.2--2012
The Code of Erection and Acceptance of Electric Power Construction Section of
Steam Boiler Set (DL/T5190.22012)
3.31996
[1996]111
Standard for Quality Inspection and Evaluation on the Commissioning of
Thermal Power Plant (1996 version)
3.41996 [1996]40

Regulations on the Start-up Commissioning of Thermal Power Plant Projects (1996

version)
3.5[2006]
Thermal Power Production Evaluation Standards by Power Construction Association
3.6DL612-1996
Supervision Code for Boiler and Pressure Vessel of the Power Industry (DL612-1996)
3.7DL5009.1-2002
Code

of

Safety

Operation

in Power Engineering

Construction

Part

1:

Steam Power Plants by Electric Power Industry Standard

3.8[2002]49
Health Safety and environment Management Regulation for Power Construction by
State Power Corporation [2002]49
3.9 DL/T852-2004
Guide for Boiler Start-Up Commissioning Test by NDRC DLT852-2004
3.10[1998]179
Performance Test Code of Thermal Power Plant Startup and Acceptance [1998]179
3.11[2000]589
Twenty-five Key Requirements to Prevent Serious Accident and Failure in
Electric Power Operation State Power [2000]589
18

3.12
Relevant contracts, design drawings, manufacture introduction, technique agreement
and other documents
3.13
Relevant regualtion and rules of state and industry
3.1 4 MCL 2150MW
Commissioning outline of Zambia MCL 2150MW coal fired power plant project

4.
Commissioning purpose
4.1
Check all equipment manufacturing and erection quality of boiler ash removal system.
4.2
Check electric and I&C protections interlock and signal devices, and confirm the
action reliability.
4.3
Check system and equipment operation, test system performance, check out and
eliminate the possible failures.
4.4

Guarantee all equipment in normal condition and safe, stable and economic operation
through ash removal system commissioning.

5
Commissioning range

19

Ash removal system commissioning including: valves open/close check, static

interlock protection test and alarm test of equipment, equipment dynamic interlock
protection test, system interlock protection test, equipment static and dynamic
startup/shutdown test, ash removal program test, ash removal system tightness test,
dynamic operation of ash removal system

6.
Commissioning condition and checking content
1

Before system commissioning, the provided condition as per content of

(appendix 1: condition checking list before integral startup) shall be checked
completely by commissioning staffs, with recording.

7.
Commissioning process, procedure and method
7.1
Commissioning procedure of ash removal system

20

2
3
4
5
6

1. System
pipe
and
equipment
erection are completed, with
complete recording.
2. I&C and electrical instruments
erection
are
completed,
calibration is qualified, and it
can put into operation.
3. Single commissioning of system
equipment is qualified.

Technique handover

Condition
commissioning

confirm

before

System valve driving test

System dynamic and static interlock test

Tightness test by starting air compressor

Dynamic program commissioning

Commissioning flow chart

21

1. Air single protection test,

cold dryer single protection
test;
2. Ash hopper gasification air
fan
interlock
protection
test;
3. Ash cellar gasification air
fan
interlock
protection
test;
4. Ash
removal
water
pump
interlock protection test;
5. Startup/shutdown
test
of
system equipment;
6. Static test of ash removal
system

7.2
Commissioning procedure and method of ash removal system
7.2.1
Open/close test of actuators
7.2.2 PLC

Open/close or change over ash removal valves through PLC to confirm local action
correction and flexibility. Channel check for important I&C signal points.
7.2.3
Gasification air system test of ash hopper:
1 1
Operation mode: one in operation and one in standby

Electrical heater startup condition: gasification air fan in operation

Gasification air fan shutdown condition: electrical heater shutdown

Gasification air fan trip, interlock shutdown electrical heater

When operating air fan trip caused by failure, interlock open standby air fan
outlet motor valve and alarm, start standby air fan.
7.2.4
Gasification air system of ash silo:
2 1
Operation mode: 2 in operation and 1 in standby

Electrical heater startup condition: gasification air fan in operation

Gasification air fan shutdown condition: electrical heater shutdown

Electrical heater trip, interlock shutdown Gasification air fan

22

When operating air fan trip caused by failure, interlock open standby air fan
outlet motor valve and alarm, start standby air fan.
7.2.5
Ash removal air compressor system
10 2
Operation mode: 10 in operation and 2 in standby
10
If pressure is low when 10 in operation, interlock start standby air compressor.
7.2.6
Cold dryer system
6 2
Operation mode: 6 in operation and 2 in standby
6 ,
When six sets in operation and one is trip by failure, interlock standby cold
dryer (firstly open outlet motor valves).
7.2.7
Ash removal startup
a.:
startup procedure of ash removal system
20
20 hours before boiler firing, put electrical heater of precipitator hopper;

72
100
72 hours before ash silo receiving ash, put ventilation to dry and open all
gasification valves of ash silo to maintain gasification air temperature at
100 by put one set of gasification air fan and one heater into operation.

Check that lube oil, cooling water, dryers and other parts of air compressor
system shall conform to startup requirement; reversely operate air conveying
system as per regulated sequence, firstly start one cold dryer and then start air
compressors one by one.

23

Filers and gas tanks of started air compressors shall be cleaned up without
deposited water.

Air source pressure of conveying and control systems shall be regulated to

satisfy pressure of ash silo pump and pipe operation, and gas tank pressure
shall meet design requirement.

Put bag filter of ash silo, air source and bag vibration shall be checked and
normal.

All hoppers, ash silo pumps, level gauges and heaters shall be checked,
which shall be at auto control position.

Manual butterfly valve of ash hopper shall be checked at closing position, put
positive pressure ash conveying system compressed air blowing into
operation; each group of ash silo pump shall be blown one time by manual,
and then put auto ash cleaning program into operation, after at least three
circulation, then into ash conveying operation.

I/ ,

Open manual butterfly valve of ash hopper, and put ash silo pump into
operation; as per principle of firstly less ash and then more ash, put ash
hopper pump of economizer, ash hopper pump of denitration, ash hopper
pump of ESP I/II field and ash hopper pump of bag dust collector into

24

operation.

When ash pumps into operation, check ash flow condition at all time, and
hammer it when it is necessary; if ash blocking is appeared, close inlet ash
valve and convert to compressed air blowing operation.
8

Before silo ash storage, all gasification pipes shall be checked without
blocking, and pipe temperature is a little hot; ash discharging shall be carried
out after 8 hours continuous storage to prevent deposit at silo bottom;
according to requirements of truck loading, put dry and wet ash discharging
devices, and one wet pump shall be started firstly before wet ash discharging
into operation.
b.
Shutdown sequence of ash system

After boiler blowing out, shutdown ash pump one by one until all ash in
hopper is completely evacuated according to ash deposit condition.

Deposit ash in silo shall be discharged completely.

60

If gasification air fan system is required to shutdown, firstly shutdown

electrical heater to wait for temperature falling under 60, and then
shutdown gasification air fan system.

Air compressors shutdown can be carried out as per system requirements.
25

8.
8.1 1996
100%
90%
Quality standard requirements of the system and equipment shall be satisfied
according to Standard for Quality Inspection and Evaluation on the Commissioning of
Thermal Power Plant (1996 version), with 100% qualified rate and 90% excellent
rate, meeting the unit startup requirements.
8.2

Commissioning professional and supervisor shall enforce check and control for key
points of commissioning quality, and report to higher level leader when find out
problems to coordinate and solve to ensure successful startup commissioning.

9.
Environment, occupational health and safety control procedure
9.1

The system shall be organized and commanded coordinately, any change by personnel
is forbidden. The commissioning shall not affect unit safety, if any event that may
affect the unit safety and stability, stop commissioning at once and recover stable
operation of the unit. When the unit is confirmed in stable condition, restart
commissioning again. The commissioning shall be organized and commanded under
headquarter.
9.2

26

All commissioning staff shall strictly carry out Safety Regulation and on-site relevant
safety regulation to ensure the commissioning safety and reliability.
9.3

If find out abnormal condition during commissioning, timely regulate and report to
leader; if exists possibility that may endanger personnel and equipment, stop
commissioning at once or shutdown the unit when it is necessary.
9.4
If abnormal situation happens during the commissioning, instantly adjust it and report
it to headquarter.
9.5
Professionals shall be on site during the commissioning to ensure the safety of
running equipment and personnel.
9.6
When carry out equipment maintenance, relevant safety measures and working orders
shall be necessary.
9.7

Before ash silo to store ash, it shall be dried completely. Before silo pump starting,
ash hopper fluidization shall be checked to guarantee when ESP into operation, the
fluidization device shall be followed into operation.
9.8

When ash silo in operation condition, working condition of bag filter shall be checked
at all time to prevent deposit, which will cause high back pressure of ash silo to block
ash conveying pipe.
9.9

When system no-load, hopper blocking and other alarm signals does not work, timely
change to manual control and check whether exist ash deposit in all units in order to
handle.
9.10
When check and measure ash pipe and pumps, change to manual operation.
9.11
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Working staffs and operators engaged in startup commissioning shall be familiar with
process flow and relevant technique standard of ash removal system.

10.
Organization and division
10.1
Erection unit
10.1.1
In charge of compiling commissioning report.
10.1.2
In charge of the system isolation and closing.
10.1.3
In charge of maintenance, overhaul and troubleshooting of commissioning equipment.
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 check and acceptance after subsystem commissioning.
10.1.7

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.

28

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.
10.3.4
In charge of test data recording and filing.
10.3.5
Engage in check and acceptance after subsystem commissioning.
10.3.6
In charge of compiling commissioning report.

10.4
Supervisory unit

In charge of supervisory work during starting and commissioning as per the contract,
supervise the procedure execution, engage in the commissioning, check and
acceptance.

11
Appendix

29

 1
Appendix 1: Checking list before commissioning condition

30


Checking list of commissioning condition

Class
No.
Item

machine

4
5
6

Commissioning procedure has been compiled

with complete approval procedure.

()
Erection is completed; secondary grouting is
completed;
relevant
pipes
(including
suspension) erection is completed.

Commission equipment is complete with

necessary nameplates; system connection is
complete.

Cooling and sealing system are complete.

Lube oil quality is qualified with normal level.

Auxiliaries (such as oil station and valves)

commissioning of large rotation machines shall

be qualified and approved.

System
manual,
motor
and
single
commissioning shall be completed with
approval sheet.

Pipe blowing and flushing shall be completed,

pipe pressure test shall be completed with

approval sheet.
,

Calibration of safety valves and pressure release

10

valves of system shall be correct with recording.

Coupling connection and protection shield of

11

rotation machine shall be complete.

No-load turning of rotation machine shall be

12

flexible.

Rotation machine centering shall be completed

13

with recording.

If exist possibility of reverse running, if adopts

14

electrical

15
16

reliable braking measures.

Electrical switch insulation shall be qualified

and recorded.
31

Electrical switch driving test shall be completed

and qualified with approval sheet.

Time

Resul
t

Remar
k


Responsible person of commissioning unit:

Responsible person of supervisory unit:

Responsible person of production unit:

Responsible person of erection unit:

Responsible person of construction unit:

Date:

32