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COMMISSIONING GROUP
COMMISSIONING GROUP
OBJECTIVE:
TO REMOVE DIRT, OIL, GREASE etc., FROM THE CONDENSATE , FEED WATER, DRIP & EXTRACTION STEAM LINES OF HP & LP HEATERS, USING A NON-IONIC DETERGENT ,PRIOR TO PUTTING THESE SYSTEMS IN REGULAR SERVICE. THIS ENSURES FLOW OF CLEAN CONDENSATE & FEED WATER TO BOILER THE FOUR STAGES OF DETERGENT FLUSHING ARE: STAGE-I: FEED LINES STAGE-II: CONDENSATE LINES & DRIP LINES OF HPH-5A & 5B STAGE-III: EXTRACTION STEAM LINES AND DRIP LINES OF HPHs STAGE-IV: EXTRACTION STEAM LINES AND DRIP LINES OF LPHs NOTE: EACH SYSTEM SHALL BE SUITABLY SUBDIVIDED INTO VARIOUS SUB CIRCUITS TO COVER ALL THE LINES AND COMPONENTS
COMMISSIONING GROUP
1)
CHEMICALS &WATER a) DM WATER : 5000T b) NON-IONIC DETERGENT RINOPOL-JET 100% 1000 LITRES (OR SUMISOL-N 100% )
@0.05%CONCENTRATION
c) FOR PASSIVATION HYDRAZINE HYDRATE -800KG @ 80% CONCENTRATION (IS:12086/1991) LIQUOR AMMONIA------ 400KG @ 25% CONCENTRATION (IS:799/1985)
2)
PUMPS AND VALVES: a) TEMPORARY CIRCULATION PUMPS ( 4Nos) CAPACITY : 200T/hr Head: 20 KG/CM2 MOTOR : 180 KW b) TEMPORARY MIXING TANK CAPACITY 40 M3 . c) VALVES & INSTRUMENTS a) b) c) d) e) f) g) STEAM SUPPLY LINE V/V (1No.) DM WATER SUPPLY LINE V/V (1No.) MIXING TANK DRAIN TO NEUTRALISATION PIT V/V (1No.) PUMP DISCHARGE SAMLE LINE V/V (1No.) DETERGENT RETURN SAMPLE LINE V/V (1No.) PUMP DISCHARGE LINE DRAIN V/V (1No.) DETERGENT RETURN LINE DRAIN V/V (1No.) 3'' 4'' 4'' 1'' 1'' 1'' 10'
COMMISSIONING GROUP
h) i) j) k) l) m) n)
TEMPORARY P/P SUCTION LINE V/Vs (4Nos) TEMPORARY P/P DISCHARGE LINE V/Vs (4Nos) PUMPS RECIRCULATION V/V (1No.) PUMPS COMMON DISCHARGE LINE V/V (1No.) PRESSURE GAUGES (0-40Ksc) (2Nos) TEMPERATURE GAUGES (0-1500C) (2Nos) LEVEL INDICATOR FOR MIXING TANK (2Nos)
3)
OTHER REQUIREMENTS a) POWER SUPPLY TO TEMPORARY CIRCULATION PUMPS(415V) b) ADEQUATE LIGHTING IN ALL WORKING AREAS c) LABORATORY FACILITY FOR ANALYSIS OF FLUSHING WATER d) SERVICE WATER e) FIRE EXTINGUISHERS f) ADEQUATE TEMPORARY PIPING & SUPPORTS
COMMISSIONING GROUP
METHOD
LINE UP THE STAGE TO BE FLUSHED FILL THE SYSTEM WITH DM WATER BY CIRCULATION PUMPS CARRY OUT COLD WATER MASS FLUSHING IN ALL THE SUB LOOPS FOR 1 HOUR, THEN CONTINUOUS RINSING TILL EFFLUENT VISIBLY CLEAR. ADMIT STEAM INTO MIXING TANK & RAISE THE DM WATER TEMP. UP TO 600C AND CARRY OUT HOT WATER MASS FLUSHING IN ALL THE SUB LOOPS FOR 2 HOUR CONT. RINSING & DRAINING OF THE < 5NTU REFILL TOTAL CIRCULATION SYSTEM WITH SYSTEM TILL TURBIDITY & ESTABLISH
DM WATER
ADMIT STEAM INTO MIXING TANK, RAISE THE WATER TEMP. TO 600C ADD RINOPOL-JET 100% OR SUMISOL-N 100% TO ACHIEVE SOLUTION CONCENTRATION OF 0.05% CIRCULATE THE SOLUTION IN EACH OF THE LOOPS FOR A MIN. DURATION OF 4 HOURS. DURING CIRCULATION GIVE MAKE UP STEAM / WATER KEEPING THE SOLUTION TEMP.AT 600C
COMMISSIONING GROUP
METHOD
DRAIN THE SYSTEM COMPLETELY & FILL IT AGAIN WITH DM WATER CIRCULATE DM WATER IN EACH LOOP FOR HOUR ONCE AGAIN DRAIN THE SYSTEM COMPLETELY RINSE THE SYSTEM WITH DM WATER BY CONTINUOUS FILLING & DRAINING TO MEET COMPLETION CRITERIA STOP THE PUMPS & DRAIN THE WHOLE SYSTEM FILL THE SYSTEM WITH DM WATER & RAISE THE TEMP. TO 600C FOR PASSIVATION ADD HYDRAZINE & AMMONIA TO GET 210PPM HYDRAZINE& PH OF WATER TO 9.5 TO 10.0. RAISE THE TEMP. TO 800C & MAINTAIN CIRCULATION FOR 8 HOURS THEN DRAIN OUT THE SYSTEM & ALL AIR VENTS & FEED STORAGE TANK MAN HOLES ARE OPENED TO AERATE THE SYSTEM MAKE INTERNAL INSPECTION OF D/A FOR FOREIGN MATERIAL, IF ANY, AND CLEAN THORUOGHLY
COMPLETION CRITERIA:DM WATER RINSING AFTER CHEMICAL FLUSHING SHALL BE CONSIDERED COMPLETE ONCE CONDUCTIVITY OF DRAINED WATER IS LESS THAN 10MICRO
COMMISSIONING GROUP
FEED CONTROL STN FEED STORAGE SH AND RH SPRAY TANK R / C LINE
PI TI STEAM SUPPLY DM WATER SUPPLY SAMPLE DRAIN TEMP TANK P/Ps R/C HPH-6B HPH-5B SAMPLE PI TI OPEN DRAIN
BP SUCTION
DRAIN
BFP SUCTION
BFP DISCHARGE
STAGE-1A
HPH BYPASS
COMMISSIONING GROUP
FEED CONTROL STN FEED STORAGE SH AND RH SPRAY TANK
PI TI STEAM SUPPLY DM WATER SUPPLY SAMPLE DRAIN TEMP TANK P/Ps R/C HPH-6B HPH-5B SAMPLE PI TI OPEN DRAIN
BP SUCTION
R / C LINE
DRAIN
BFP SUCTION
BFP DISCHARGE
STAGE-1B
HPH BYPASS
COMMISSIONING GROUP
POINT NEAR ECO I/L
FEED CONTROL STN FEED STORAGE SH AND RH SPRAY TANK STEAM SUPPLY DM WATER SUPPLY R / C LINE TEMP TANK
BP SUCTION
DRAIN
HPH BYPASS
HPH-6B HPH-5B
BFP SUCTION
BFP DISCHARGE
PI
TI
STAGE-1C
OPEN DRAIN
LPH-3 BYPASS
COMMISSIONING GROUP
DEAERATOR
LPH-2 BYPASS
LPH-3
HPH-5A
DM WATER SUPPLY
LPH-2
LPH-1 B.P
R/C
DRAIN CLR.
SAMPLE TI
BLANK / FLANGE
STAGE-2A
OPEN DRAIN
LPH-3 BYPASS
COMMISSIONING GROUP
DEAERATOR
LPH-2 BYPASS
LPH-3
HPH-5B
DM WATER SUPPLY
LPH-2
LPH-1 B.P
R/C
DRAIN CLR.
SAMPLE TI
BLANK / FLANGE
STAGE-2B
OPEN DRAIN
COMMISSIONING GROUP
DEAERATOR
5A DRIP TO D/A
STEAM SUPPLY
SAMPLE DRAIN
HPH-6A
HPH-5A
HP FT
P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B
R/C
HPH-6B
HPH-5B
5B DRIP TO D/A
SAMPLE
PI
TI
BLANK / FLANGE
TEMPORARY PIPING
STAGE-3A
OPEN DRAIN
COMMISSIONING GROUP
DEAERATOR
5A DRIP TO D/A
STEAM SUPPLY
SAMPLE DRAIN
HPH-6A
HPH-5A
HP FT
P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B
R/C
HPH-6B
HPH-5B
5B DRIP TO D/A
SAMPLE
PI
TI
BLANK / FLANGE
TEMPORARY PIPING
STAGE-3B
OPEN DRAIN
COMMISSIONING GROUP
DEAERATOR
5A DRIP TO D/A
STEAM SUPPLY
SAMPLE DRAIN
6A DRIP TO 5A
HPH-6A
HPH-5A
HP FT
P/Ps R/C
6B DRIP TO 5B
HPH-6B
HPH-5B
5B DRIP TO D/A
SAMPLE
PI
TI
BLANK / FLANGE
TEMPORARY PIPING
STAGE-3C
OPEN DRAIN
COMMISSIONING GROUP
DEAERATOR
5A DRIP TO D/A
STEAM SUPPLY
SAMPLE DRAIN
HPH-6A
HPH-5A
HP FT
P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B
R/C
HPH-6B
HPH-5B
5B DRIP TO D/A
SAMPLE
TI
STAGE-3D
OPEN DRAIN
COMMISSIONING GROUP
DEAERATOR
5A DRIP TO D/A
STEAM SUPPLY
SAMPLE DRAIN
HPH-6A
HPH-5A
HP FT
P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B
R/C
HPH-6B
HPH-5B
5B DRIP TO D/A
SAMPLE
TI
STAGE-3E
OPEN DRAIN
COMMISSIONING GROUP
DEAERATOR
5A DRIP TO D/A
STEAM SUPPLY
SAMPLE DRAIN
HPH-6A
HPH-5A
HP FT
P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B
R/C
HPH-6B
HPH-5B
5B DRIP TO D/A
SAMPLE
TI
STAGE-3F
OPEN DRAIN
COMMISSIONING GROUP
TEMPORARY LINE TO MIXING TANK
TEMP
LP2 DRIP TO LP1
TANK
LP FT
LPH-1
P/Ps
SAMPLE
PI
TI
BLANK / FLANGE
TEMPORARY PIPING
STAGE-4A
OPEN DRAIN
COMMISSIONING GROUP
TEMPORARY LINE TO MIXING TANK
TEMP
LP2 DRIP TO LP1
TANK
LP FT
LPH-1
P/Ps
SAMPLE
PI
TI
BLANK / FLANGE
TEMPORARY PIPING
STAGE-4B
OPEN DRAIN
COMMISSIONING GROUP
TEMPORARY LINE TO MIXING TANK
TEMP
LP2 DRIP TO LP1
TANK
LP FT
LPH-1
P/Ps
SAMPLE
PI
TI
BLANK / FLANGE
TEMPORARY PIPING
STAGE-4C
OPEN DRAIN
COMMISSIONING GROUP
TEMPORARY LINE TO MIXING TANK
TEMP
LP2 DRIP TO LP1
TANK
LP FT
LPH-1
P/Ps
SAMPLE
PI
TI
BLANK / FLANGE
TEMPORARY PIPING
STAGE-4D
OPEN DRAIN