PREPARATION FOR

COMMISIONING OF
BOILER
 WHAT IS THE DIFFERENCE OF
COMMISIONING & OPERATION

 Commissioning-construction
&assembling stage

 Operation-execution
Construction of Boiler
 Four columns will be erected
 Drum lifting (Critical activity)
 Economiser coils-header
 Reheater,superheater-hanger supports
 Water walls
 Parallel activities- RAPH, Milling system,
Fans
Agencies of power plant
commissioning

 Customer - NLC
 Supplier- BHEL
 Consultant- Tata consultants
 Duration to construct a
power plant

 Feasibility report- D.P.R- project

status,capacity,fuel used, technical
parameter

 Minimum 4 years( from the d.a.c )

Part -I
1. Need for commissioning procedure
2. Objectives of commissioning
3. Different agencies of commissioning
 Part-2
1.Auxiliary Steam header charging
2.Oil system flushing
3.One series ID/FD/RAPH to be made ready
4.Pressure parts inspection-SH,RH.ECO,DRUM
5.Firing systems- Mills, oil burners
6.Thermal flow test
7.Alkali Boil out
8.Acid cleaning
9.Passivation
10.Hydrotest
11.Steam blow-out
12.Protection &interlock checking
13.Commissioning of sampling points
14.Inspection of expansion joints, critical hangers, peep hole doors, manhole doors
15.Safety valve floating
16.Checking chemical valves
17.Synchronization,Load raising,optimisation
Part-3
Miscellaneous Activities
 Walk down inspection
 Critical hanger inspection
 Buck stay inspection
 PRDS commissioning
 WSB, WL, RSB,SSB commissioning
 Furnace fouling analysis
 Air& Gas tightness test
 LPD operation
Auxiliary steam header charging-18
kg/cm2, 43.5 t/hr, 250ْc, 46 m/sec

 AST requirement- 20 t/hr

 Oil atomization 1.5 t/hr
 Fuel oil heater-1.65 t/hr
 SCAPH 16.25 t/hr
 Oil line trace heating 2.0 t/hr
 De-aerator 16 t/hr
 Ejector-3.5 t/hr
 1. AST –Header charging
 Open the drains
 Partial opening of incoming steam valve
 Wait for 3-4 minutes
 Ascertain steaming through drain valves
 Close the drains
 Open the incoming steam valve gradually
 Observe the raise in pressure in pr.guage
 Charging is completed if valve is 100%
opened
Mistakes during AST charging
 Fail to open the drains

hammering
hanger supports
fails
Remedial action
 Close the incoming steam valve
immediately.
 Open the drains fully
 Wait till hammering stops
 Follow the procedure from beginning
2. Oil line flushing
 What is the need for oil line flushing ?
 Where is oil lines located in boilers ?
 How the line is flushed ?
 How many times flushing to be done ?
3. One series of ID/FD fans
made ready
ID fan commissioning procedure

FAN

ELECTRICAL MECHANICAL INSTRUMENT

Electrical
 HT motor , 6.6 KV
 Motor will be erected and aligned
 If alignment not proper, use fillers
 Cable connection to be given
 Give power supply
 Give “ kick” start and stop ( Annex or UCB )
 Check DOR
 If wrong ,correct it
 Commission motor bearing switches- DE,NDE
 Motor lubrication &cooling
 Trial run of motor without coupling with fan
 How long trial run ?
Mechanical
 Main parts of ID fan-impeller, bearing, blades,
lubricating oil system, damper
 Impeller and bearing erection to be done
 Check for alignment by dial gauge without blades
 Give oil connections through rubber hose/metallic-for
lubrication purpose
 Before admitting oil inside the bearing check for
purity of oil- how ?
 Commissioning of oil pumps, cooling air fans
 Should be satisfied with alignment, oil pressures-
lubricating oil pr., control oil pr
Instrument
 Limit setting of discharge damper
 Commissioning of pr. Switches,
temperature switches,RTD
 PCD calibration-translational movement
of servomotor piston is turned into
rotation (VIA) lever
 Vibration sensors
Temperature switches-types
 RTD –resistance temperature difference, it is
used to monitor tempt. From UCB.upto 200°C
can be used . Rs 200-300
 RTD with ( limit valve monitor)ex -RAPH
 Temperature switches-local indicator-signal
goes to switch, but no indication in UCB, but
you get annunciation hi/v hi, costs 1,50,000
 When tempt. to be measured is > 200° C use
thermocouple. for >1500°C use pyrometer
etc
Protections of ID fan
1. Control oil pressure = 14 kg/cm2
2. Lubricating oil pressure=3kg/cm2
3. If control oil pr < 8 bar, reserve starts
4. If control oil pr < 6 bar, fan trips
5. If lube. Oil pr < 0.8 bar, reserve starts
6. If lube. Oil pr. < 0.5 bar, fan trips
7. Fan brg. Tempt. 90/110° C
8. Fan brg. Tempt < 50°C, lube pumps can be stopped
9. If diferential pr across filter >1.2 bar change the filter
10. Fan motor brg. Tempt 90/110° C
11. Oil tank level low< minimum, fan trips
Fan commissioning
 confirm checking of all
electrical,mechanical,instrument connections
through check lists
 Couple motor and fan
 Give supply
 Check local conditions
 Give start command
 Follow set defined procedures after giving
“ON “ command
Problems after starting the
FAN

electrical mechanical

instruments
Electrical faults
1. Locked rotor protection(LRP)-mechanical obstruction<2 secs
2. Differential protection- check for megar valve, 1 kv=1 mega
ohm, then 6.6kv=7 mega ohm. Check in each phase you
should get 7 mega ohm. If you get < 7 mega ohm either
moisture or oil ingress. If mega ohm is 0 then puncture in
insulation
3. Short circuit protection
4. Negative sequence protection
5. Earth fault protection
6. Thermal overload protection-heating characteristics, fan
cooling. greasing for lubrication of windings
Mechanical faults
1. Local latch
2. Fan bearing tempt. Contact
3. Oil pr. Protection contact etc
Instrument fault
1. PCD min. contact
2. Tempt. Contact
3. Pr. Switches contact
4. If false pick , then bypass or if it is
real then attend to the fault
 FD fan
 FD fan
commissioning-same
procedure
RAPH
SALIENT POINTS
 Motor alone trial run for 8/12/24 hrs
 Erection of hot/cold end baskets

 Adjust the seals, recommended seal gap 3-6 mm

 Manual rotation of RAPH

 Commission lube oil system

 Commission speed sensor

 Commission tempt. Switches for guide /support bearing (RTD),
HI/V.HI =60/70°C, reset valve 58/68°C
 Cooling water system, ACW

 Commission fire fighting and RAPH washing lines

 Commission RAPH soot blower lines

Firing systems Mixed firing

Lignite firing

oil firing
Oil flushing
 Flush oil lines with steam initially alone during
commissioning by keeping vents and drains
opened
 If leak observed attend to it
 Charge oil trace heating line with steam
 Charge with oil gradually by starting oil
pumps from FOPH
 Put oil under recirculation upto QCV near
burner station
Oil firing system
 Erection of oil burners
 Commissioning purge, atomizing, oil lines
 Commissioning of limit switches in oil, steam
lines-check for its limit contact i.e open/close
contact
 Commissioning of IR/UV scanners, with
cooling lines from SAF
 Check for any chokes or foreign particles in
tip of oil gun by air blowing
Milling system
 Motor (6.6 kv) alone to trial run
 Mill wear plate checking for uniform alignment
 Without fixing beater wheel , rotate manually and
check mechanical hardness
 Commission lube oil system, with flow meters
 Commission mill bearing tempt. Switches
 Commission motor bearing tempt. switches
 Charge ACW line
 Inspect RSD – refractory healthiness, uniformity
 After checking all fittings fix the wheel then close
the mill
Commissioning of SH/RH/ECO
 Erection as per drawing
 Check for any misalignment like sagging of headers
etc.
 Check the critical hangers for their “cold” condition, if
not inspect the hanger
 Provision of metal tempt. Thermocouples for
SH,RH,ECO,Drum both left/right sides
 Fixing pr.guages,tempt. Gauges at local also contacts
for UCB indication
 Drum to be inspected for cyclone separator fixing,
level switches,transmitters,hydrastep,local guage
glass
Chemical cleaning of boiler
 Alkali boil out-it is cleaning of internals
for efficient heat transfer- removes
lubricants,oil,rust
 Acid cleaning-scales, deposits removal
 thermal flow test
 Passivation-to avoid internal corrosion,
a anticorrosive coating is formed called
magnetite using hydrazine
Testing of boiler
 Hydro test-1.5 times of working
pressure
 Steam blow out-to check purity of
steam, removal of welding slag
Protection&interlock checking
 Before boiler is lighted, P&I to be done
 Start RAPH , follow defined procedure
 Put ID/FD in “TEST” position with electrical help from annex, allow oil
pumps to run
 Conduct pr, tempt. Switch contact from the field for both fans
 Go to RH2 i/l to check furnace vacuum switches. LHS 2+, 1 – RHS
2-, 1+
+250mmwcl ,-300mmwcl for 2 sec or more
If pr is low then ID trips, if high then FD trips
 Check mill protections, mill bearing tempt. Contact by putting mills in
“test” position
 Check RAPH protections , GB/SB bearing tempt contact by c&I
 Fill the boiler contour, check high level and low level
+330/-340 for 5 sec, boiler will trip( can be done while filling)
Inspections/checking
 Commissioning of sampling points
 Inspection of expansion joints, critical
hangers, peep hole doors, manhole
doors
 Safety valve floating
 Checking chemical valves
 Synchronization, Load
raising,optimisation
 Chemical valves
conden Feed drum Sat.steam Super
sate water heated
steam
sio2 .02 .02 .3 .02 .02

Fe .02 .02 .02 .02 .02

cu .01 .01 .01 .01 .01