Boiler IDF and System Commissioning Procedure

Compiled by:

Reviewed by:

Approved by:

2014

Qingdao Huachen Weiye Electric Power Technology Engineering Co., Ltd.

Catalogue

31. overview

32. main equipment technique specification

73.commissioning basis and standard

84.commissioning purpose

85.commissioning condition

86.commissioning process and method

117.commissioning instrument and equipment

118. commissioning quality and assessment standard

129.Environment, occupational health and safety control procedure

1210 organization and division

1511.Appendix

Boiler IDF and System Commissioning Procedure

1. Overview

ZMTP 2150MW2510t/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 IDF 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.

Main equipment technique specification

2.1

Boiler specification

Zambia MCL 2150MW Coal Fired Power Plant2510t/h150MWZambia 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, tube-type air preheater, balanced draft, end part double flue, suspension structure, half-unsheltered 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 BMCRBECR

Main steam flowT/H510485.73

Main steam pressure MPa14.3214.32

Main steam temp. 540540

LP RH inlet pressure MPa2.852.85

LP RH inlet temp.334334

HP RH inlet pressureMPa2.72.7

HP RH inlet temp.540540

RH flowT/H420.42400.4

Feed water temp. 248248

Feed water temp. exclusive all HP171

#1

Feed water temp. exclusive #1 HP228.6

#2

Feed water temp. exclusive #2 HP207.3

(LHV)

Boiler guaranteed efficiency (LHV)90

Boiler desulfurization efficiency 92.3

2.2

Fan technique parameter

IDF system mainly comprises following equipment: two IDFs, two IDF motors, two hydraulic couplings, two sets of auxiliary equipment of hydraulic coupling, control and protection.

IDF mode and type Mode: centrifugal 1854AZ/1715 Type: 1854AZ/1715 Blade mode: dual-draft mode, wing shaft blade.2 Rotation direction: two sets turn to right, while two sets turn to left (see from motor to air fan)

24Layout mode: symmetry laying, two sets for each boiler, and total four sets for the project. 1150SVNL Hydraulic coupling type: 1150SVNLSTMKK50-6L 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 STMKK50-6L, produced by Xiangtan Motor Company. 1Sheet 1: IDF design parameter Performance point IDF flowInlet temp. Inlet negative pressure Full load pressure rising

Nm3/hPaPa

TBT, B point 425020153.4-74617700

BMCRDesign (BMCR)354185138.4-51815300

2Sheet 2: IDF regulation No. Item Manufacturer filling

1Mode Dual-draft, dual supporting, centrifugal

2IDF quantity for each boiler 2

3 %Selected point efficiency (full pressure) %88.7

4 %Guaranteed point efficiency (full pressure)88.6

5

TBSelected working condition

TBkg/hQuality flow (kg/h)548401

6m3/hCapacity flow (m3/h)764856

7kPaTotal head pressure (kPa)

8Inlet medium temp. ()148.8

9kWShaft power (kW) 1900.9

10

BMCRCalculated working condition

(BMCR) kg/hQuality flow (kg/h)457040

11m3/hCapacity flow (m3/h)599004

12kPaTotal head pressure (kPa)1082.3

13Inlet medium temp. ()133.8

14kWShaft power (kW) 1045.7

15Shell material Q235A

16 mmShell thickness (mm)10

17Shaft material 45#

18/Blade wheel material 15MnV

19/ Blade wheel service life ( 10,000 hour)10

20 tRotor weight (t)9000

21 tTotal weight (t)35000

22Bearing mode Rolling bearing

23Bearing lubricating mode Oil bath lubricating

24 m3/hAllowed minimum stable flow (m3/h)40000

25

Driven motor Manufacturer Xiangtan motor

26Type YKK710-6

27 kWRated power (kW)2100

28 VVoltage (V)6600

29 r/minRotation speed (r/min)980

30Protection grade IP55

31Cooling code -Air-air cooling

32Bearing mode Sliding bearing

33Neutral point current transformer Dalian Zhongguang

34Flow control mode +Inlet damper + hydraulic coupling

3Sheet 3: hydraulic coupling performance parameter Name Unit Rated load Max. Design value

Output power KW

Slip%

Slip loss KW

Fixed loss KW

Input power KW

Input speed r/min

Output speed r/min

Rotation direction According to owner requirement

Driving shaft Rotating direction is identical with the motor.

Driven shaft Rotating direction is identical with the motor.

Speed control range As per operation plan As per operation plan

Working oil pump mode

Lube oil pump mode

Startup oil pump mode

Working oil pressure MPa.g

Working oil flow l/min

Lube oil pressure MPa.g

Lube oil flow l/min

Oil cooler

Design pressure of working oil cooler MPa.g/

Design pressure of lube oil cooler MPa.g/

Design temperature of working oil cooler OC

Design temperature of lube oil cooler OC

Cooling area of working oil m2Shall be submitted after signing agreement.

Cooling area of lube oil m2Shall be submitted after signing agreement.

Cooling water

Water flow of working oil cooler t/hShall be submitted after signing agreement.

Cooling water pressure drop of working oil cooler MPa.gShall be submitted after signing agreement.

Water flow of lube oil cooler t/hShall be submitted after signing agreement.

Cooling water pressure drop of lube oil cooler MPa.gShall be submitted after signing agreement.

Introduction:

1.TB(test block)

TB (test block): allowance shall be reserved for air flow and pressure in TB working condition. 2.BMCRBMCRBMCR: 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. 4.180The IDF can bear 180 of medium temperature in failure condition, and can operate safely under the temperature. 5.The IDF is controlled by hydraulic coupling. 3. Commissioning basis and standard 3.1 DL/T5437-2009Code for Fossil Power Construction Project from the Unit Commissioning to Completed Acceptance by NationalEnergy Administration DL/T5437-2009

3.2 DLT852-2004Guide for Boiler Start-Up Commissioning Test byNDRC DLT852-20043.3 DL5009.1-2002Code of Safety Operation inPowerEngineering Construction Part 1: SteamPowerPlantsby ElectricPowerIndustry Standard3.4 DLT 5210.2-2009Code for Construction Quality Acceptance and Evaluation of Electric Power Construct. Part 2: Boiler Unit by NationalEnergy Administration DLT 5210.2-20093.5 1996Standard for Quality Inspection and Evaluation on the Commissioning of ThermalPower Plant (1996 version)3.6 1996Regulations on the Start-up commissioning of Thermal Power Plant Projects (1996 version) 3.7 Relevant contracts, design drawings, manufacture introduction, technique agreement and other documents. 3.8 MCL 2150MWCommissioning outline of Zambia MCL 2150MW coal fired power plant project. 4. Commissioning purpose 4.1In order to guide and regulate system and equipment commissioning, and put into operation safely and normally, hereby the procedure is compiled. 4.2Check electric and I&C protections interlock and signal devices, and confirm the action reliability. 4.3Check equipment operation and systems performance, find and remove the possible problems.5. Commissioning condition 1Before commissioning, the commissioning staff shall check the provided condition completely for the system as per appendix 1 content and make recording.6. Commissioning process and method IDF system commissioning work can be carried out as per following flow chart:

Chart 1: Commissioning flow chart 6.1Actuator check 6.1.1 Check and accept motor air valve dampers, record data; 6.1.2Check and accept motor control air valves, record data. 6.2 Thermal signal check 6.2.1 Check and accept analog and switching value signal, record data. 6.2.2For above signal, on site position shall be considered to analyze the reality of collected signal, if not, response and suggest to construction unit. 6.2.3Air 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. 6.3 Interlock protection and alarm signal check 6.3.1 IDF power switch shall be at test position. 6.3.2 Check following items: DCSDCSStart IDF on DCS with correct response; DCSDCSShutdown IDF on DCS with correct response; 6.3.3 Emergency button works normally. 6.3.4 IDF protection test shall be completed as per content of interlock protection sheet, which shall work normally. 6.3.5IDF and its system commissioning 6.3.5.1Following conditions shall be checked, confirmed and satisfied: 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 IDF and its system erection are completed. e) Air channel of IDF shall be cleaned up without any foreign materials that may cause air fan damage. f) Manholes of IDF outlet air channel and body shall be closed. g) Air valves and dampers shall be checked and qualified. h) I&C erection and verification shall be qualified. i) Interlock protection driving test related to IDF shall be qualified, and protection and alarm setting shall be completed. j) Electrical test and electrical interlock test shall be completed. k) IDF emergency button driving test shall be completed and qualified. l) Manual turning IDF and its rotor shall be normal. m) Insulation resistance of the motor shall be measured and qualified. 6.3.5.2Protection or interlock that does not affect safety shall be cut off and recorded. 6.3.5.3IDF startup preparation a) Carry out check as per auxiliary code before startup, which shall be qualified. b) CRT Confirm that IDF inlet and outlet dampers shall work well, and local opening shall be identical with CRT display. c) Confirm that IDF bearing is filled with qualified lube oil. 6.3.5.4Switch on IDF power and checka) Whether IDF rotation direction meet design requirement or not; b) Whether exist abnormal sound or not; c) Whether the system exists obvious leakage or other abnormal situation. 6.3.5.530DCSIf no abnormal situation, restart IDF after 30 minutes, then gradually control parameter of IDF control damper and hydraulic coupling, supervise IDF current to prevent overcurrent operation. Record all operation parameter (local and DCS data shall be recorded separately). 6.3.5.6Operation parameter shall be supervised during operation, which shall be in normal range. 6.3.5.7Check the system leakage and air channel vibration. 6.3.5.88IDF and its system commissioning shall be kept for 8 hours, then shutdown the IDF and record the idle hour. 6.3.5.9After IDF shutdown, cut off IDF power. 6.3.5.10The air channel shall be freely flowing to prevent vibration caused by air valve misoperation closing. 6.3.6System operation during the complete set operation 6.3.6.1168The system reliability shall be checked as per no load stage, on-load stage, full load stage and 168 hours operation. 6.3.6.2The system dynamic control. 6.3.6.3The equipment supervision shall be enforced during system operation, especially during furnace negative pressure control to ensure that the system in optimal operation condition. 6.3.6.4 Fill in commissioning record. 7.Commissioning instrument and equipment Vibration gauge Revolution meter Infrared radiation thermometer

Clip-on ammeter Phonometer8.Commissioning quality and assessment standard1996100%90%Quality standard requirements of the system and equipment shall be satisfied according to Standard for Quality Inspection and Evaluation on the Commissioning of ThermalPower Plant (1996 version), with 100% qualified rate and 90% excellent rate, meeting the unit startup requirements. The air fan operation shall be stable and normal; bearing bush temperature and vibration, cooling water system and motor coil temperature are normal. Professional commissioning staff and supervisor shall strictly check and control the 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.Environment, occupational health and safety control procedure 9.1 When IDF and its system first startup, relevant staff shall be on equipment site to supervise strictly with reliable communication to control room. 9.2 ,When IDF test running, startup time and current shall be supervised strictly, instantly shutdown if startup current is too long or current fluctuates rapidly. 9.3 If equipment damage or personal casualty maybe happened or has been existed, instantly stop commissioning and analyze the cause to propose resolution measures. 9.4 When IDF starting, rotation direction shall be monitored, if the direction is reverse, instantly shutdown. 9.5 On-site safety regulation shall be carried out strictly by all commissioning staff to guarantee the reliability. 9.6 If abnormal situation happens during the commissioning, instantly adjust it and report it to headquarter. 9.7 Pay attention on supervising change of bearing vibration and temperature to prevent heavy accident. 9.8 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. 9.9 Relevant systems, such as inlet and outlet flue channel, ESP, desulfurization, denitration, steel inner shell of flue, etc. shall be closed and checked to ensure that there are no person in above area. 10Organization and division 10.1Erection unit 10.1.1In charge of organization of subsystem commissioning. 10.1.2In charge of the system isolation and closing. 10.1.3In charge of maintenance, overhaul and troubleshooting of commissioning equipment. 10.1.4Prepare necessary overhaul tools and material. 10.1.5Coordinate with the commissioning unit to carry out subsystem commissioning. 10.1.6In charge of temporary mark on relevant system and equipment. 10.1.7In charge of check and acceptance after subsystem commissioning.10.2Construction unit 10.2.1In charge of equipment startup, shutdown, operation control and accident elimination during the commissioning. 10.2.2In charge of formal mark for relevant systems and equipment. 10.2.3Prepare operation regulation, tools and record sheet. 10.2.4In charge of inspection and normal maintenance for commissioning equipment. 10.3Commissioning unit 10.3.1In charge of compiling commissioning procedure and technique handover. 10.3.2Prepare relevant measuring instrument, apparatus and tools. 10.3.3Engage in subsystem commissioning. 10.3.4In charge of test data recording and filing. 10.3.5Fill in inspection and qualification sheet of commissioning quality. 10.3.6Engage in check and acceptance after subsystem commissioning.10.3.7In charge of compiling commissioning report. 10.4Supervisory company 10.4.1In charge of supervisory work during starting and commissioning as per the contract, supervise the procedure execution, engage in the commissioning, check and acceptance. 10.4.2 In charge of organization of system isolation and acceptance. 10.5IDF subsystem commissioning and single commissioning shall be charged by erection unit, and coordinated by commissioning unit and other relevant units. The IDF and its system commissioning shall be carried out by professionals, coordinated by boiler, electrical and I&C, commanded under headquarter. 11.Appendix 1 Appendix 1: Checking list for IDF commissioning condition No. Checking content Requirement Date Result Remark

1-1IDF and its system erection Complete with recording

1-2IDF and air channel erection Complete

1-3IDF and air channel cleaning Complete

1-4Lube oil quantity of all bearings Normal

1-5Cooling water system Qualified water pressure, in operation.

1-6Desulfurization area and air flue closing and check Complete, closing document is accepted.

1-7Denitration area and air flue closing and checkComplete, closing document is accepted.

2-1Motor electrical test 2Test is qualified with correct direction after 2 hour no load running.

2-2 IDF and its system air valves Flexible operation, correct direction.

2-3Measuring meter Correct indication, after verification.

2-4

Electrical and I&C protection, interlock and signal deviceTest is qualified.

2-5Inlet control damper Qualified control and correct direction.

2-6Power Reliable

3-1On-site road The road is unblocked with sufficient illumination and emergency illumination.

4-1On-site communication equipment Convenient and available

4-2Firefighting facilities Sufficient

4-3Maintenance staff (including electrical and thermal staff)Enough and trained

4-4 Maintenance tools and material Enough

4-5 Operation tools and recording sheet Readied

4-6Test instrument and apparatus Readied

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:

2 Appendix 2: Commissioning record IDF system air valves KKSKKS No. Name Local indication correct Remote operation Time Checking dateChecking result Signature Remark

Correct direction Correct response Open Close

XXXXXXXXAA IDF inlet damper

XXXXXXXXAA IDF outlet damper

XXXXXXXXBB IDF inlet damper

XXXXXXXXBB IDF outlet damper

XXXXXXXX

XXXXXXXX

XXXXXXXX

XXXXXXXX

3 Appendix 3: IDF system interlock protection test card

No.

Test content

Result

Remark

IIDF

Startup permitted condition

1