Air Compressor System Commissioning Procedure

Compiled by:

Audited by:

Approved by:

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

2014

Catalogue11

1Introduction

12

1Equipments Introduction

33

3Compile Basis

44

4Commissioning purpose

45

4Trial Run Conditions

56

5Commissioning Methods and Steps

97

9Commissioning Quality Check Standards

108

10Obligations and Divisions

129

12HSE Control Measures

1410

14Appendix

1 Introduction 40m3/min440m3/min1220m3/min2

In this project, there are 4 40m3/min water-cooling no-oil instrument air compressors, 12 40m3/min water-cooling no-oil conveying air compressors and 2 20m3/min water-cooling no-oil maintenance air compressors. Through compressor system commissioning, remove system defects; blow pipes and the system to make equipments and system output and main technology parameters as design required and provide stable and reliable compressed air for all air equipments and confirm whether the whole system meets unit general commissioning and trial run conditions. 2 Equipments Introduction

Zambia MCL 2150MW Coal Fired Power Plant( MCL 2150MW)2510t/h150MW2.1 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, 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.2.2

Air compressor . instrument air compressors 4manufacturer Shanghai Ingersoll Ran d

modelSM250exhaust flow41.5 m3/min

exhaust pressure0.8 Mpacooling modewater cooling

cooling water flow19.6 m3/h cooling water pressure 0.6 Mpa

exhaust temperature 40cooling water temperature below 32compress stage 2

2blast type air purify device (2)air dryers Q=90Nm3/min ,P=0.8MPa prefiltersQ=90Nm3/min ,P=0.8MPa

post filtersQ=90Nm3/min ,P=0.8MPa

air storage tank 4 V=25m3,P=1.0 MPa

main motor model Y2-400-4

rated power 250 KWrated Vol. 6.6 KV

Speed1475 rpmRated cur.16.73 A

. Conveying air compressor12manufacturer Shanghai Ingersoll Rand

modelSM250exhaust flow 41.5 m3/min

exhaust pressure0.8 Mpacooling modewater cooling

cooling water flow19.6 m3/h cooling water pressure 0.6 Mpa

exhaust temperature 40cooling water temperature below32 compress stage 2

9blast type air purify device (9)Q=60Nm3/min ,P=0.8MPa

air storage tank12 V=30m3,P=1.0 MPa

2 V=20m3,P=1.0 MPa

2 V=10m3,P=1.0 MPa

main motor model Y2-400-4

rated power 250 KWrated Vol. 6.6 KV

Speed1475 rpmRated cur.16.73 A

. maintenance air compressor 2manufacturer Shanghai Ingersoll Rand

modelSM132exhaust flow 21.4 m3/min

exhaust pressure0.8 Mpacooling modewater cooling

cooling water flow9.6 t/h cooling water pressure 0.6 Mpa

exhaust temperature 40cooling water temperature below32 compress stage 2

main motor model LS315

rated power 132 KWmain motor model 400 V

Speed2950 rpmrated power 246 A

3 Compile Basis

2150MW "Zambia Maamba 2150MW Coal-fired Power Plant Startup and Commissioning Outlines"

DL/T5437-2009Code for Fossil Power Construction Project from the Unit Commissioning to Completed Acceptance DL/T5437-2009[2000]589Twenty-five Key Requirements to Prevent Serious Accident and Failure in ElectricPowerOperation State Power [2000]589DL5009.12002Code of Safety Operation inPowerEngineering Construction Part 1: SteamPowerPlantsby ElectricPowerIndustry Standard1996The Code of Erection and Acceptance of Electric Power Construction Section of Steam Boiler Set (1996)[1996]111Standard for Quality Inspection and Evaluation on the Commissioning of ThermalPower Plant (1996 version)1996Regulations on the Start-up Commissioning of Thermal Power Plant Projects (1996 version)Equipments manufacturer materials, drawings and equipments manuals

Operation regulations compied by power plant4 Commissioning purpose 4.1 Each air compressor system trial run 4.2 Each air purify system trial run.

4.3 Blow compressed air system pipes.

4.4 Air compressors group interlocks.

5 Trial Run Conditions 5.1.1 System equipments and pipes erections finished as required; base strength as design required; electric CB cabinets wiring correct and firm. 5.1.2 Construction facilities removed; ditches and holes have complete covers onsite; ground flat, ways free and lights sufficient. 5.1.3 Thermometers, pressure gauges calibrated and erected; cooling water system qualified after flush and running conditions satisfied. 5.1.4 Air compressor proper system finished and startup requirements satisfied before trial run. 5.1.5 Before started, manufacturer must be on site and the compressor oil level as required. 5.1.6 Air compressors erection finished and the communicating equipments prepared as manufacturer required. 5.1.7 Lub oil and cooling water system can be run normally. 5.1.8 Air compressor single motor trial run qualified; dry and regenerating filters qualified after trial run. 5.1.9 Air compressor system pipes and relevant accessory equipments erected as design required and the suspending and supports complete and reliable. 5.1.10 Dryers erection finished and pipes, electric circuits satisfy energizing requirements. Blow and clean the pipes section by section before dryers. Air compressor supply conditions are satisfied before dryers commissioning. 5.1.11 Control system erection and commissioning finished; relevant interlock and protections reliable and correct by driving, which can be run normally. 5.1.12 Confirm compressors auto loading and unloading pressure settings as manufacturer required. 5.1.13

Air compressor proper, oil filters, air purify devices, dust filters and air and water separators commissioning finished. 6 Commissioning Methods and Steps 6.1 Air compressor trial run

6.1.1 Under manufacturer instruction, after conditions satisfied, trial run air compressors. 6.1.2 Before primary startup, manually run free wheel several circles to check whether there is strike or other sounds and prevent compressor burnt caused by lack oil. Then start compressor for trial run. 6.1.3 Check following data on air compressor panel: exhaust pressure and temperature, cooling water pressure, inlet air temperature, back coolers exhaust temperature, air compressor motor current. 6.1.4 During trial run, record above data as well as startup current and time; measure motors temperature and vibration and record relevant parameters. 6.1.5 Pay attention whether compressor has loud noise and whether motor current is normal in trial run. 6.1.6 Confirm oil filters, air purify device, dust filters and air and water separators work well. 6.1.7 Air compressor's exhaust temperature is normal. 6.1.8 20-30Run compressor without load 20-3omin. 6.2 Trial run air purify device

6.2.1 Under manufacturer instruction, after conditions are satisfied, trial run dryers. 6.2.2 Before primary startup, blow compressed air pipes to prevent sundries into dryers and filters. 6.2.3 0.7MPStart air compressor, when system pressure is approaching to 0.7MPa and compressor running normally, start dryers. 6.2.4 3Close air switch and connect with power; at the time, power indicating light on panel is on and control system is auto into 3min delay. 6.2.5 3Set transferover switch on manual position and press startup button; after 3min delay, dryers will be auto started and when running indicating light is on, it means dryers are running. 6.2.6 5-100.3-0.5MP,1.2-1.8MPAfter observe 5-10min, air processed by dryers will satisfy use requirements and at the time, cold medium LP gauge in 0.3-0.5MPa and cold medium HP gauge in 1.2-1.8MPa. 6.2.7 Slowly open brass valve on auto drainer to make condensate in air go into drainers and then be drained out of compressors. 6.2.8 Interlock startup and stop mode: put transfer switch on interlock position. Dryers are started by air compressors and controlled by stop signal, dryers can be auto run. When dryers need manual stop, put switch on manual position to stop dryers. 6.2.9 Remote control mode: put transfer switch on remote position. Dryers are started by remote and controlled by stop signal, dryers can be auto run. When dryers need manual stop, put switch on manual position to stop dryers.6.2.10 Dryers fault alarm functions: when the working dryers have fault alarms, equipments will be auto stopped and controller will output fault alarm signals, the machine alarm indicating light is on and the fault signals output to remote. Notice: after equipments stopped by faults, users must press stop button to quit dryer fault alarm state. 6.2.11 If machines need be stopped, on local mode, press stop button to stop dryers and on remote control mode, input remote stop signals to stop the dryers. Close inlet and vent valves. 6.2.12 Notice: 1 Avoid dryers running without load long time. 2 5It is prohibited to start and stop dryers continuously in short time. At least 5min intervals should be satisfied to prevent damaging refrigeration compressor. 3 When power lost suddenly, 2 inlet pneumatic valves of dryers will be auto opened and 2 regenerating VV will be auto closed. After power recovered, slowly increase 2 towers pressure to normal working pressure, then press start button and controllers start working. One of both towers goes into sucking state and another one will reduce pressure and be into regenerating state. 6.3 Blow compressed air system pipes

6.3.1 Scope: All air header and branch pipes in boiler and ST house. 6.3.2 0.7MPSteps: start 1 air compressor and close outlet valve of air storage tank. When tank outlet pressure increased to 0.7MPa, open tank outlet valve to blow main pipes and then take control through each branch pipes valves to blow each branch pipes till main pipe outlet air clean. 6.4 Air compressor group interlock

6.4.1 After air compressors receive startup signals, interlock and remote control will be auto realized. When one air compressor receives startup signal, auto operation will be realized. 6.4.2 0.6MP0.8MPWhen air supply header pipe pressure below 0.6MPa, the spare air compressor will be auto started to remain header pipe pressure at 0.8MPa. 6.4.3 When instrument air header pipe pressure keeps down and the running air compressor on fault, the air compressors in maintain spare state will be auto started to satisfy system normal running requirements. 6.4.4

If the spare air compressor receives startup signals but refuse starting, alarm signals will be sent out for fault disposal in time. At the same time, manually start other spare air compressors. 7 Commissioning Quality Check Standards

7.1

Articles related to air compressors in "Commissioning and Trial Run Quality Check and Assess Standards for Thermal Power Project"7.2

Relevant regulations in manufacturer manuals. 7.3 Each system pipes have no leakage or jam.

7.4 No abnormal noise at bearing rotary parts and bearing temperature as manufacturer technology standards required (if no manufacturer standards, state standards as basis)

7.5 Running parameters as design or manufacturer technology required.

7.6

Through observing storage tank charging time and actual air consumption, judge whether flow satisfies parameters regulated in technology agreement by manufacturer; if the deviation is obvious larger, require manufacturer to take flow measurement. 8 Obligations and Divisions 8.1 Produce Unit

Finish necessary produce preparation, i.e. compile operation regulations and system drawings, operators training and relevant equipments nameplate hanging; participate in air compressor system partial trial run and acceptance after the trial run; start and stop equipments, make running adjustment, record running parameters and take routine checks in trial run. 8.2 Construction unit

Finish single equipments trial run and acceptance related to air compressor system; submit single equipment trial run records and relevant documents and materials; take charge in safety, firefighting, defecting and maintenance on air compressor system trial run site. 8.3 Owner Organize and manage air compressor trial run, participate in checks and coordination in equipments trial run preparation step, handover acceptance, erection and commissioning acceptance. 8.4 Commissioning unit

Compile commissioning procedure; check air compressor system and the integrity and rationality; participate in single equipment trial run related to air compressor system; play technology responsible role in air compressor system trial run and finish compressor system trial run; participate in acceptance after partial trial run and fill in the commissioning and trial run assess table and bring out commissioning summarization. 8.5 Consultant unit

Take consultant in air compressor and the system commissioning steps, supervise carrying out the procedure and participate in trial run and the acceptance. 9 HSE Control Measures

9.1 When air compressor and system started firstly, erection, commissioning, operation and manufacturer people must be on site for supervision. 9.2 During trial run, stop equipments at once if some may risk human or equipments safety. Carry out "3 No Startup" principles. 9.3 Stick warning signs around starting device. 9.4 Before changing pressure parts, isolate the unit and pressure resource reliably and release system pressure. 9.5 While air compressor starting, pay attention to motors rotary direction. If it is run conversely, equipments should be stopped at once. 9.6 Before unit running, check whether pressure, temperature and time setting is correct and whether control and stop device functions normal. 9.7 Confirm whether the acoustic insulating materials on tank, compressor inlet and exhaust systems good to guarantee noise is not increased. 9.8 Temporary system exhaust must avoid passerby and be fixed firmly, not face to other buildings. 9.9 While blowing, around the exhaust, there should be people supervising, patrolling and inspecting. Irrelevant people should not get close. 9.10 It is prohibited to run air compressor over exhaust pressure limited on nameplates. 9.11 Take intermittent water drain on dryers. Because water will reduce dryers efficiency even make dryers invalid due to poison. 9.12 While blowing system, the exhaust should not face to equipments with reliable isolations. 9.13 During trial run, pay attention to control panel information and handle the found problems in time. 9.14 In winter, the storage tank water discharge valve should be opened often to prevent the condensate water freeze off valves. 10 Appendix

Air Compressor Trial Run Records

TimeAir compressor exhaust pressure Air compressor exhaust Temp.Air compressor current cooling water Temp.Vib.

motor side air compressor side

MPaA

: :Recorder: Date:

1