06 procedure of start up boiler ok

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06 procedure of start up boiler ok

  1. 1. PLTU 1 Jatim-Pacitan (2×315MW) Project Procedure of Start-up Boiler B Revised as comments 13/11/2010 Liu Gang Long Sheng Zeng Bin Zhang Yaping A For approval 8/2/2009 Liu Gang Long Sheng Zeng Bin Zhang YapingRev. Description Date Prepared Checked Reviewed Approved Owner’s DWG PT.PLN(PERSERRO) 0702-00-M-01-QH-001 No. PT REKADAYA PT.PLN(PERSERRO) ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI CONSORTIUM OF DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY DETAIL SiChuan Electric Power DESIGN PLTU 1 Jatim-Pacitan (2×315MW) Project Commissioning & Test Institute STAGE Approval Check Review Design Procedure of Start-up Boiler Date Scale N/A DWG No. SCCTI-TS-GL-CS-006-2009A REV B
  2. 2. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV BCommissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 2 of 44 Table of Contents 1. Purpose ............................................................................................................. 3 2. Scope .................................................................................................................. 3 3. Preparation Basis ................................................................................................ 3 4. Brief Description of System and Equipment...................................................... 3 5. Tools and Instrument for Commissioning .......................................................... 4 6. Prerequisite for Commissioning ......................................................................... 4 7. Measures for Commissioning Organization....................................................... 7 8. Commissioning Procedure.................................................................................. 9 9. Safety Measures................................................................................................ 34 9.1 Safety rules for commissioning ........................................................................ 34 9.2 Personal Risk and Preventative Measures........................................................ 34 9.3 Equipment Risk and Preventative Measures .................................................... 35 10. Appendix .......................................................................................................... 36 10.1 Appendix 1 Commissioning Condition Checklist............................................ 36 10.2 Appendix 2 Format for Trial Run Record ........................................................ 40 10.3 Appendix 3 Pressure boosting curve-boiling out ............................................. 40 10.4 Appendix 4 Pipeline Blowing System Diagram............................................... 41 10.5 Appendix 5 Check list of dampers ................................................................... 43 10.6 Appendix 6 Check List of Control Dampers.................................................... 44
  3. 3. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 3 of 441. Purpose1.1 Provide a guideline and set specifications for the commissioning work of system and equipment so as to guarantee that the system and equipment will be able to put into operation normally and safely.1.2 Check the reliability of electric and I&C interlock protection and signal device.1.3 Check the operation conditions of equipment. Examine performance of system so as to find out and eliminate possible defects.2. Scope The procedure is applicable to commissioning of startup boiler, including check and confirmation of adjustment condition, valve baffle test, interlock protection test, drying, boiling, pipe blowing and steam tightness test of startup boiler, safety valve calibration, normal operation and shutdown of the boiler.3. Preparation Basis3.1 Operation Manual for Startup Boiler4. Brief Description of System and Equipment4.1 Brief introduction of the System One 40t/h oil-fired start-up boiler, produced by Jiangsu Shuangliang Boiler Co., Ltd., is equipped in PLTU 1 Jatim-Pacitan (2×315MW) Project. Model: SZS40-1.25/350-YC water tube oil-fired package boiler.4.2 Main Technical Specifications of System Device4.2.1 Main Technical Specifications of Boiler: No. Name Unit Values 1 Boiler Parameter (1) Boiler Maximum Continuous Rating T/h 40 (2) Outlet Steam Pressure MPa 1.25 (3) Outlet Steam Temperate ℃ 350 (4) Inlet Water Temperature of Economizer ℃ 20 (5) Temp of flue gas ℃ ≤160 (6) Oil Pressure before Furnace MPa 5.3 2 Technical Performance (1) Boiler Efficiency % 92.7
  4. 4. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 4 of 44 No. Name Unit Values (2) Gross Power of Supporting Auxiliaries kW 165 (3) Load Change Scope %BMCR 30~100 (4) Steam Temperature Deviation Range ℃ 345~370 (5) Boiler Blowdown Rating % ≤2 Split type atomizer (6) Type and Arrangement of Burner / burner, single and front wall arrangement4.2.2 Type of Steam Boiler Auxiliaries (1) Burner : supplied by boiler manufacturer, RPD90L-R (2) Forced draft fan: supplied by boiler manufacturer, GMB-32, 43000m3/h, 6000pa, 110KW, 380v (3) Water feed pump: supplied by boiler manufacturer, DG46-30×8, 46m3/h, 2.0Mpa, 55KW, 380v (4) Water box: supplied by boiler manufacturer, QR40,25m3 (5) Blowdown flash tank: supplied by boiler manufacturer, φ1500, 3.5 m3, 127℃5. Tools and Instrument for Commissioning5.1 Walkie talkie;5.2 Handheld vibration meter;5.3 Digital multimeter;5.4 Handheld thermodetector6. Prerequisite for Commissioning Before formally beginning system commissioning, commissioning persons should conduct comprehensive checks on conditions that should be available for commissioning of this system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and make well the records. There are turn over package(TOP)from contruction that mention contruction already finish and ready to be commissioned. Please see Appendix 1 Commissioning Condition Checklist and running parameter table of the FDF & Water pump (on section No.8.2).6.1 Prerequisite Required before Trial Operation of System6.1.1 Flue Gas and Air System (1) Boiler air pressure test has been successfully completed through acceptance or each air leakage has been treated.
  5. 5. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 5 of 44 (2) Boiler proper and flue gas duct have been assembled and insulated. (3) Individual commissioning and subsystem commissioning of forced draft fan have been completed. (4) All dampers of flue gas and air systems have been inspected, adjusted and accepted.6.1.2 Fuel Oil System (1) System has been assembled and individual commissioning has been completed. (2) System hydraulic pressure test and water flushing has been completed successfully. (3) Compressed air pipeline and valves for blowing should be assembled and tested. (4) All motorized valves and pneumatic valves for systems have been tested and accepted. (5) The burner has been assembled and tested. (6) All interlock protection simulation test for systems have been successfully completed (7) The ON/OFF tests for all oil guns and high-energy igniters have been successfully completed. (8) Static commissioning for all flame detectors has been completed. (9) Please see oil gun test table of the boiler (on section No.8.2).6.1.3 Boiler Proper (1) Boiler proper have been installed, insulated and accepted; (2) Individual commissioning and interlock protection test for water feed pump have been completed. (3) Hydrostatic tests of the boilers have been successfully completed; (4) The drain, vent, blowdown and nitrogen charging systems of the boilers have been installed and insulated. All motorized valves have been tested and accepted. (5) After hydrostatic tests, hydraulic valve spools have been removed from all safety valves of the drums and superheaters, the safety valves have been restored to original state or states. Blind plates have been removed from steam and water systems. (6) Spring supports and hangers of steam and water pipeline are complete and in good order and pins have been removed. (7) All motorized valves and pneumatic valves on all steam and water pipeline have been tested and accepted. (8) The parties check jointly the boiler proper expansion systems to confirm that boiler expansion is not restrained. (9) Ladders, platforms and railing on boiler proper are complete and illuminated sufficiently and the boiler proper has been cleaned thoroughly. (10) Drum level gauges have been installed, the level is indicated correctly. (11) Boiler water samplers and dosing systems have been installed, inspected and accepted correctly.
  6. 6. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 6 of 44 (12) Feed water system, desuperheating water systems have been installed and insulated. All motorized valves and pneumatic valves have been tested. (13) All manholes and access doors on the boiler proper are complete and closed; (14)Please see running parameter table of the water pump (on section No.8.2).6.1.4 Compressed Air System (1) Instrument& service air compressors have passed commissioning individually or as a subsystem and are ready for use.6.1.5 Fire Protection System (1) All fire fighting facilities are complete, fire water tests have been successfully completed and the systems are at standby state. (2) Fire fighting equipments have been equipped at boiler house, control room and place with fuel oil systems.6.1.6 Industrial Water System (1) Industrial water systems have been installed and hydrostatic tests have been successfully completed. (2) Commissioning of industrial water pumps and industrial water subsystems have been completed and pumps and systems are ready for operation.6.1.7 Chemical Water System (1) The chemical system is able to supply water continuously. (2) Commissioning of make-up water systems has been completed.6.2 Conditions that must be available with electrical and I&C Please see running parameter table of the FSSS, sequence control of boiler start andstop ) and interlock (on section No.8.2). (1) Cold commissioning of the boiler FSSS (fuel oil systems and the burner) has been completed 1) Furnace blowing conditions have been checked and tested; 2) Fuel oil FSSS tests and interlock test (performed after the FSSS test) have been completed; 3) The fuel oil leak test has been completed; 4) Combustion management systems for all oil guns have been tested. (2) Sequence control, interlock and protection test of each auxiliary device has been completed; 1) Starting conditions, tripping conditions, program-controlled startup and program-controlled shutdown of forced draft fan 2) Starting conditions, tripping conditions, program-controlled startup and program-controlled shutdown of water feed pump (3) Electric and I&C have been calibrated and are accurate.
  7. 7. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 7 of 44 (4) For flue gas and air systems, measuring points of air temperature and pressure, furnace negative pressure, pressure switch, flue gas temperature and pressure of heating surface of different grade have been installed and are ready for operation. (5) For steam and water systems, measuring points of drum pressure, superheater pressure, steam temperature, feed water pressure, temperature and flow, steam flow and water level meter with electric contacts have been installed and tested and are ready for operation. (6) For fuel oil system, measuring points of fuel oil pressure and temperature, flow meters, compressed air pressure have been installed, tested and are ready for operation. (7) Measuring points of auxiliary current, bearing temperature and vibration have been installed, tested and are ready for operation. (8) Commissioning of various protections, alarms and visual and audio signals has been completed and they are able to generate alarms properly.6.3 Conditions Required for Environment (1) The field is leveling; road is clear; cover on trenches are complete; wastes have be cleared. (2) Platforms, ladders, railings protecting sheets are complete; construction scaffold have be removed. (3) Site is sufficiently illuminated. Temporary illumination can be arranged if necessary. (4) Communication device is complete. Reliable communication equipment should be equipped.6.4 Other Conditions Required (1) The construction contractor, builder, Owner, Supervisor, Manufacturer and testing agency inspect the entire units thoroughly to confirm that the unit is ready for ignition. Problem found must be solved immediately, if any. (2) Preparation for trial operation has been completed and operators have been assigned, trained sufficiently and examined. Operation procedures and system drawings have been reviewed and approved and operating tools and log are available. (3) Chemical products and material required for commissioning have been prepared. Sufficient amount of chemical water, fuel oil and coal have been prepared according to the design requirements. (4) Necessary maintenance tools and materials are prepared. (5) A sound commissioning management organization has been established and the responsibilities have been clearly defined. (6) Commissioning material, tools, instrument and record lists have been prepared. (7) Instrument control, electric and engineering personnel are on site.7. Measures for Commissioning Organization This procedure shall be executed under the organization of commissioning contractor. The construction contractors shall cooperate closely with each other according to their respective work responsibilities so as to guarantee safe and effective implementation of commissioning. The division of works is as follows:
  8. 8. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 8 of 447.1 Responsibilities of Commissioning Contractor Preparation and revision of commissioning procedures; Preparation of commissioning plan; Preparation of instruments and equipment required for commissioning; Hold technical disclosure meeting for commissioning; Organize the commissioning work to be carried out by various parties; Give instructions to operators in the operation; Prepare commissioning report.7.2 Responsibilities of Installation Contractor Be responsible for individual commissioning of equipment and provide relevant record and certificate of commissioning; Be responsible for inspection, maintenance and defect elimination of equipment under commissioning; Prepare maintenance tools and materials necessary for commissioning; Assist the commissioning contractor in the commissioning of subsystems; Be responsible for temporary coordination of local I&C components and connection terminals.7.3 Responsibilities of Equipment Manufacturers Representative of manufacturer, if present on the site offering service, shall provide technical assistance during equipment commissioning.7.4 Responsibilities of Plant Operator Prepare tools to be involved in operation; Prepare operation log and forms; Operate the system and equipment according to the operating procedures and the instructions of the commissioning personnel; Be responsible for patrol inspection, check, and normal maintenance of system and equipment; Be responsible for dealing with the accidents occurred in commissioning。7.5 Responsibilities of Dongfang Electric ◆ Be responsible for supervision and control over commissioning work; ◆ Coordinate with commissioning contractor, the Owner, and other contractors in the commissioning. ◆ Participate in and witness the commissioning work; ◆ Organize analysis and settlement of major technical issues in commissioning。7.6 Responsibilities of Owner
  9. 9. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 9 of 44 ◆ Supervise the execution of commissioning procedures; ◆ Witness the commissioning work; ◆ Accept the results of commissioning。8. Commissioning Procedure8.1 Test of Valves (1) Test and accept motorized (solenoid) on off valve, and record data. (2) Test and accept pneumatic on off valve and record data. (3) Test and accept pneumatic adjustable valve and record data. See Appendix 5 and 6.8.2 Interlock protection and alarm check (note: interlock protection test is subject to the results of logic discussion) (1) Put the power supply of fans and water feed pump at testing position (2) Check the flowing items: (3) Start the fans or water feed pump on computer and the feedback on computer is right. (4) Stop the fans or water feed pump on computer and the feedback on computer is right. (5) Operation of the emergency button is reliable. (6) Interlock protection of start-up boiler system is as the following: Record table of water feed pump start and trial operation Waterfeed pump Trial operation First start Second start Name unit Normal running ( no load ) ( no load )Start current ANormal running current ABearing TEM. ℃( Non Drived side )Motor bearing TEM. ℃( Drived side )Vibration ( Drived side ) mm/sVibration ( pump side ) mm/sCompleted By SEPCTI DEC PLN JASERSignature
  10. 10. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 10 of 44Date Record table of FDF start and trial operation FDF Trial operation First start Second start Name unit Normal running ( no load ) ( no load )Start current ANormal running current ABearing TEM.(Non Drived ℃side)Motor bearing TEM. ℃(Drived side)Vibration(Drived side) mm/sVibration(fan side) mm/sCompleted By SEPCTI DEC PLN JASERSignatureDate Boiler interlock checklist of FSSS No. Test item Fixed value Results Remarks1. Action conditions of FSSS Protection(1) Act emergency shut-off button(1) FDF Stopped(2) Feed water pump Stopped(3) Drum water level low (1 of 2),190mm boiler shut-off and ≥190mm alarm(2) Oil fuel loss(oil inlet pressure low 2.0MPa or return oil Inlet ≤2.0MPa pressure high 1.0MPa ) Return ≥1.0MPa
  11. 11. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 11 of 44(3) Drum and superheater pressure high(1 of 2)(drum 1.33 ≥1.33MPa MPa and superheater 1.29 MPa) ≥1.29MPa(4) Oil gun has put into service and furnace oil flame detector no flame (loss flame, delay 8s)(5) Feed Air pressure low ≤10mbar2. Boiler Fault reset(or)(1) Reset button on DCS(2) Reset button on PLC control cabinet3. Furnace purge(conditions meet ,time 2 min.) (and)(1) The FDF has been running and inlet air damper is opened to more than 70%(2) no flame of the flame detector(3) No FSSS protection action(4) All oil feed and return valves closed(4 valves)(5) The lamp of boiler startup is ready for startup(6) Drum water level is normal4. Results of FSSS protection action(1) Oil gun tripped and closed all oil feed and return valves(4 valves)(2) Ignitor solenoid valve close and forbid ignitor to fire5. Open condition of Oil gun feed valves(and,2valves)(1) Open instruction of oil gun feed valves give out(2) No FSSS protection condition(3) Small gas gun has been running6. Trip condition of Oil gun feed valves(or,2valves)(1) Boiler shut-off instruction give out(2) Any one of FSSS protection action exists7. open condition of Oil gun return valves(and,2valves)(1) Open instruction of oil gun return valves give out(2) No FSSS protection condition
  12. 12. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 12 of 44(3) Small gas gun has been running8. Trip condition of Oil gun return valves(or,2valves)(1) Boiler shut-off instruction give out(2) Any one of FSSS protections action exists9. Boiler sequence control(1) Boiler sequence start: Boiler startup instruction give out , start FDF motor, automatically open air damper to more than 70%, automatically start purging furnace for 1 min.; then automatically close damper to 20% position, then program automatically give out light instruction.(details: first, high power ignitor automatically light, then automatically light up small gas gun ;after about 3s, automatically light big oil gun and automatically open oil 4 feed/return valves. after 5s, automatically stop small gas gun. The flame detector detect flame and exist, mean the startup process is success. If not, after 5s, the flame detector is no flame, the startup process is failure.(2) Boiler sequence stop: Press shut-off button, automatically close all oil valves, inlet air damper of FDF automatically open to 70% position and automatically start purging process for 2 min.. after completed purging, This air damper automatically close and stop FDF motor.Completed By SEPCTI DEC PLN JASERSignatureDate Interlock checklist of water pump and water& steam system No. Test item Fixed value result remark1. Trip condition :(or)(1) Motor fault tripped
  13. 13. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 13 of 442. Start condition:(and)(1) Feed water control valve put into less than 10% position(2) Startup instruction give out(3) Power control cabinet is ready3. Stop condition:(and)(1) Power control cabinet is ready4. Interlock open of Desuperheater control valve(1) Superheater outlet steam TEM. more than fixed value5. Interlock close of Desuperheater control valve(1) Superheater outlet steam TEM. less than fixed value6. Interlock open of Feed water control valve(1) ≤230mm Drum water level low (less than 230mm)7. Interlock close of Feed water control valve(1) ≥260mm Drum water level high (more than 260mm) Open of main steam valves (all conditions are met)8.(1) Send command to open valve(2) Power supply of main steam valves is not broken(3) State of program control Close of main steam valves (all conditions are met)9.(1) Send command to close valves(2) Power supply of main steam valves is not broken(3) State of program controlCompleted By SEPCTI DEC PLN JASERSignature
  14. 14. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 14 of 44Date Interlock checklist of FDF and system Fixed No. Test item result remarks value1. Trip condition :(or)(1) Send command to stop FDF(2) MOTOR fault trip2. Start condition:(and)(1) Feed air damper place in less than 10% position(2) Power supply cabinet is ready3. Stop condition:(and)(1) Power supply cabinet is readyCompleted By SEPCTI DEC PLN JASERSignatureDate Boiler signal alarm checklist No. Test item Fixed value result remarks Drum water level high high, alarm and close feed water ≥300mm(1) control valve ≤190mm(2) Drum water level low low, boiler shut down and alarm ≤200mm(3) Water box water level low low, alarm ≥1.33mpa(4) Drum pressure high high, boiler shut down and alarm ≥1.29mpa(5) Superheater pressure high high, boiler shut down and alarm
  15. 15. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 15 of 44 ≥360℃(6) Superheater outlet STEAM TEM. High, only alarm(7) Feed water pump overload, boiler shut down and alarm(8) FDF overload, boiler shut down and alarm ≤2.0mpa(9) Main pipe inlet oil pressure low, boiler shut down and alarm ≥1.0mpa(10) Return oil pressure low, boiler shut down and alarm(11) ≥150℃ flue gas Temp. high, only alarm(12) ≤10mbar Inlet Feed Air pressure low, boiler shut down and alarm(13) Abnormal flame loss, boiler shut down and alarm(14) Startup failure ,boiler shut down and alarm(15) ≥5kpa Furnace pressure high, only alarmCompleted By SEPCTI DEC PLN JASERSignatureDate Test record format for oil valve leakage check No. Result (local confirmation) Tight not leakage Slight leakage Serious leakage1 feed solenoid valve2 feed solenoid valve3 return solenoid valve4 return solenoid valveCompleted By SEPCTI DEC PLN JASERSignature
  16. 16. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 16 of 44Date Test Record Format for Oil Gun Atomization OutputAtomization piece Atomization inspection Output determination Specification Local FO. press. DCS counted output Atomization angle Atomization effect (t/h) (1.5-3.5MPa) output(t/h) (t/h) A1 1.5 MPa A1 2.5 MPa A1 3.5 MPaCompleted By SEPCTI DEC PLN JASERSignatureDate8.3 Drying8.3.1 Purpose There is moisture in newly-built furnace wall. If putting it into operation directly without slow drying treatment to increase its strength, the moisture in furnace wall will generate some stress because of volume expansion caused by sudden evaporation, which may lead to crack, deformation and damage to furnace wall, even collapse if serious. So, drying under low burning according to requirements is a must before putting the boiler formally into operation. According to the special type of water wall, the long period time of boiler installation and local weather, the boiler maker need not to do the boiler drying work. This information will provided to owner before system commissioning.8.3.2 Conditions required before drying (1) Boiler proper and its auxiliary device have been installed, insulated and pass the air leakage test. The waste inside have been cleared and air leak test of furnance wall is qualfied. (2) Main steam pipeline system, water feed system have been installed and pass the hydraulic pressure test. (3) Brick laying, heat insulation and finishing of start-up boiler have been completed. Open every access door to dry the boiler naturally over 72 hours. (4) Device in drum has been completed. For water level meters, level mark is clear, position is correct, and illumination is sufficient to read the water level.
  17. 17. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 17 of 44 (5) Relevant water releasing system have been installed. Water feed pump can feed water to boiler at any time. (6) Remote operation of I&C, sound, light and audio signal, and installed and checked protection device can be put into operation. (7) Feed demineralized water to the drum water level -30mm, and flush the water level meter clearly. (8) Cooling water system has been installed and pass the water test. (9) Water discharge system has been completed. And discharge is smooth. (10) Daily oil tank has been installed. Oil tank has been cleared, and oil pipeline has been blown clearly. (11) Fuel oil system between oil tank and start-up boiler has been installed, insulated, blown throughly by compressed air, are with normal hydraulic pressure and ready for oil supply. (12) All auxiliary device, valves and dampers of boiler have been tagged. (13) Each rotatory machine has passed commissioning as a subsystem. (14) On and off of steam and water valves, flue gas and air dampers of boiler have been checked. Their movement is flexible, on-off direction and marks are correct. (15) Safety protection system of boiler has been tested. (16) Necessary illumination should be arranged for access road and equipments in commissioning field. Road is clear; cover on trenches and holes are complete. Communication is ready for clear liaison. (17) Steam trap on superheater is on to maintain normal pressure in drying. (18) Started oil guns of burner on boiler is well atomizedl, burn normally and pass service test. (19) The uniform commissioning organization of sufficient number of operators, maintenance personnel and security personnel shall be built. The operators shall be trained suitably and be familiar with the associated equipments and systems and operating methods and aware of commissioning measures, their own responsibilities and works to prevent incorrect operation.8.3.3 Methods and Steps (1) Close manhole of bottom drum, handhole of header, main steam valves, exhaust steam valves, blow down valves and drain cock of level meter. (2) Inject demineralized water, with temperature lower than 40℃, into boiler through economizer to the low water level of boiler (-20—-30mm), and close the water feed valve. When the water level in boiler is stable, observe whether the level decreases and check whether water leaks from the cover of the handholes, flange joint and blowdown valves. If not, bolts should be fastend and maintain low water level in boiler.(-20—-30mm) (3) Check whether oil tank has oil, oil pipeline leaks and oil and pipeline heaters are put into operation. (4) Start forced draft fans and adjust the damper regulator to blow the furnace.
  18. 18. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 18 of 44 (5) Ignite with firewood. Control the combustion intensity by outlet flue gas temperature of furnace. Control the flue gas temperature strictly. On the first day, the rise does not exceed 50℃. Later, the rise does not exceed 80℃ every day. At last stage, highest temperature of flue gas does not exceed 160℃. Highest temperature does not last for over 24 h. During the drying, the water level of boiler should be maintained normal. Drying period should be controlled according to the degree of natural drying. During the drying, do not use hard fire, open exhaust steam valve to release air to keep no pressure in boiler, and heat slowly to avoid blow hot and cold to prevent the insulating layer of fire proof material from cracking and damage. Keep no pressure rising in drum, steam pressure for drying is not higher than 0.1MPa. Note: Installation contractor should make temporary racks inside boiler to keep wood.8.3.4 Safety Notice for Drying During the drying, fully open steam trap on superheater and exhaust steam valve at outlet of superheater. (1) Flame should be controlled from light to strong and burn in the center uniformly to ensure uniform exotherm. Check furnace wall and expansion state of each part frequently, report the abnormal situation timely, if found. (2) During drying, strictly control the water level in drum, maintain it in normal scope, and feed water timely. (3) Before drying, reserve discharge holes for moisture at proper position. (4) After drying, prepare temperature rise curve and relevant records. Boiler drying record table Date/time Drum water level(MM) Outlet TEM. of furnace (℃) RemarkCompleted By SEPCTI DEC PLN JASERSignatureDate8.4 Boiling out8.4.1 Purpose
  19. 19. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 19 of 44 Eliminate high temperature oxidation peel-roll, corrosion products, welding slag, silt, oil stain and other debris produced in rolling, processing, storage and installation. Generate protection layer in the inner wall to prevent corrosion, maintain the heating surface of boiler clean, increase the steam and water quality to prevent encrustment and corrosion, save fuel, extend life span and ensure safe and economic operation of boiler unit.8.4.2 Scope and process of alkaline boil-out (1) Scope: water screen system, lower drum, upper drum (the part under the flushing centerline of upper drum ) (2) Washing: three steps are conducted for washing: Flush with lots of water before washing; Boil out the boiler with chemicals; Flush the boiler with hot water after washing.8.4.3 Conditions required before boiling out (1) Hydraulic test has been completed and tested. (2) Commissioning of water feed pumps, induced draft fans and forced draft fans has been completed. (3) Chemicals for boiling out and containers for disolution have been prepared. Commissioning of chemical feed pump has been completed successfully. (4) Chemical water system can continuously supply enough demineralized water with sound quality. Flushing and recovery of dosing system have been completed and the system is ready for operation at any time. (5) Operator of power generator should be on duty and report state of water quality at any time. (6) Temporary indicator lights to indicate high, low and normal water level are equipped at control room the platform of drum, which have been prepared and accepted. (7) Operator and installation and maintenance people can operate and prepare necessary tools. Inspection and preparation for igntion should be done in advance according to Operation Specification before boil-out so as to make startup and ignition upon commands. (8) Systems have been tagged. Correct and clear marks is with various equipments, valves and flow direction of medium.8.4.4 The following systems should be commissioned before boiling out. (1) Flue Gas and Air System: The inside has been cleared cleanly, checked and accepted. Dampers have been adjusted, checked and accepted. Individual commissioning of forced draft fan has been passed. (2) Fuel Oil System Hydraulic pressure test has been passed. Blowing has been completed;
  20. 20. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 20 of 44 Fuel oil circulating is qualified; Fire control device relevant to fuel oil have been tested and accepted. (3) Water Feed System 8-hour individual commissioning of water pump has been completed successfully; Flushing of water feed pipeline has been completed successfully; Relevant interlock test has been completed successfully. (4) Dosing system is ready for operation (5) Industrial water system is ready for operation (6) Ignition system of boiler Atomization and service tests have been completed. Ignition device has been tested normally. (7) All instruments of boiler have been assembled tested and are ready for operation. (8) Relevant valves of boiler have been assembled tested and accepted. (9) Water drainage systems are ready for use. (10) Water feeding system are ready for use. (11) Blowdown system of boiler are ready for use. (12) All other systems that impact ignition of boiler8.4.5 Method and Procedures (1) Boiler working and hydraulic pressure test 1) Check that the system meets the requirements for hydraulic pressure test 2) Send water to boiler with water feed pump. In hydraulic test, ambient temperature should be over 5℃ above zero. Frost protection measures should be taken when temperature is under 5℃. Temperature of water used for hydraulic test should be over the ambient dewpoint temperature so as to prevent dew formation on the surface of boiler. The temperature should not be very high in order to prevent evaporation and high temperature difference. The temperature is usually within 20℃-70℃. 3) Close the air vent when water comes out from them continuously. Boost pressure slowly at speed within 0.10—0.15MPa/min. Stop boosting pressure if abnormal situation is found. 4) Boost pressure to 0.40MPa and fasten bolts of manholes, inspection holes and flanges. 5) Boosting pressure to 0.98MPa. Stop to check completely whether leakage or abnormal situation exists. 6) If nothing is abnormal, boost pressure continuously to 1.29MPa and maintain for 20min to check whether leakage or abnormal situation exists. 7) Hydraulic test is passed if: No water drops and spray on metal wall or welding.
  21. 21. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 21 of 44 No residual deformation after the test. No leakage at connection to economizer. Boiler Record format Of Hydraulic test item result remarksNo water drops and spray on metal wall or welding □Yes □NoNo residual deformation after the test □Yes □NoNo leakage at connection to economizer □Yes □NoCompleted By SEPCTI DEC PLN JASERSignature 8) After passing hydraulic test, release pressure and water. During the pressure reduction, clean I&C tubes, chemical sample tubes and water drainage pipes. 9) Flush boiler with water. (2) Preparation of chemicals and dosing 1) After the hydraulic test, feed water to 1/3, Stop and check system and isolate the water feed and drainage and blowdown system. Add chemicals slowly into the container while agitating. After the chemicals dissolve, feed the solution to the upper drum. Start the water feed pump of boiler to send water to the low level in drum. 2) Dosing amount: sodium hydroxide (NaOH) 4 kg per m3 water; trisodium phosphate (Na3PO4) 4 kg per m3 water (calculated according to 100% purity quotient). Water volume is 25m3 (normal operating water volume in manufacturers specification) 3) Dosing Requirements: Before cleaning, feed NaOH or Na3PO4 •12H2O slowly to the container at several times, and feed demineralized water (or soft water) to dissolve chemicals sufficiently for future use. No solid chemicals can be fed directly into the boiler. 4) After feeding chemicals, feed water to flush the container 2 to 3 times. 5) After ignition, supervise water level in drum to maintain normal level. No full water is allowed. No water comes into superheater. 6) Strictly control burning capacity in the first ignition and pressure boosting. Considering the expansion in the funnel of furnace wall and temperature difference between upper and lower wall of drum, pressure boosting rate can not be too fast, increasing to 0.2MPa-0.4MPa within 2 hours. Maintain the pressure and flush water level meter. Inform the installation contractor to tighten the screws in hot state. Boost the pressure to
  22. 22. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 22 of 44 0.80MPa within 5 to 6 hours. Maintain pressure at 0.8-1.0MPa for boiling out. 7) Record expansion of each part under the following situation: Before and after feeding water, 0.4Mpa, 0.8MPa, 1.0MPa. Any part found to impact the expansion should be reported timely to stop increasing pressure. Continue boosting pressure after eliminate defect. 8) Start timing when the pressure raises to 0.8MPa. Maintain pressure within 0.8-1.0MPa for 24 hours in boiling out. Steam drainage volume is 10%-15% of the rated evaporation. 9) After 240hour boiling out, maintain pressure of boiler, and each blowdown point discharge waste and change water. This moment, strictly supervise water level in drum and prohibit full and lack of water. 10) After feeding chemicals, take furnace water sample by chemical method to test alkalinity once every two hours. In the later stage of boiling out, test can be done once every one hour. 11) Normally shut down boiler after boiling out. Decrease pressure and drain water. 12) After the temperature decreases, open the manholes on upper and lower drum and lower header of water wall to clear away internal foreign matters.8.4.6 Boiling precautions (1) Agitate homogeneously when adding chemicals. Must not lift alkaline chemicals on shoulder or with hands. Operators should ware rubber overshoes, gloves and protection masks. Cold water resource and relevant chemicals should be arranged in place where prepare and add chemicals. (2) No water comes into superheater in boiling out. Strictly supervise the water level in drums and arrange experienced operators as far as possible to adjust feed water timely. (3) Closely watch the state of each rotary machine and expansion of boiler proper. Solve problems timely, if found. (4) In boiling out, one local level meter is set in drum, and one regulated pressure gauge is used. Assign people to watch the water level and inform water feeder timely. (5) Pipeline irrelevant to boiling out should be isolated completely. Prevent washing liquid in key system from getting into other systems to avoid accident. (6) In boiling out, blocked blowndown pipeline and valves should be cleared timely, if found. (7) In field, road should be clear, illumination should be sufficient, warning sign as "Washing! Dangerous! " etc. should be pasted, and guard rail and fence should be set. (8) In washing field, flushing water taps, soaps, towels and emergency medicine (3 L 0.2% boric solution, vaseline or scream to cure scald) and emergency car should be prepared, and also take necessary protection measures. If the alkali solution splashes onto skin or into eyes, flush with fresh water immediately, and then neutralize with 0.2% boric solution and flush with fresh water again. Ones seriously hurt should be sent to hospital for rescue immediately. (9) After boiling out, the manhole can be opened until the temperature of drum wall decrease to under 50℃ with monitoring of people. When the nuts could be loosen after
  23. 23. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 23 of 44 2 to 3 threads, use a wooden stick to unclench door of manhole (No people face the door directly). After the inside negative pressure disappears, open the door of manhole and assemble reticular close board on it. (10) If no measures are mentioned for some conditions, execute the "Boiler Operation Specification". If accident occurs, deal with it according to Specification for Accident Handling. Boiler record format of boiling-out 3- Date/time Drum pressure(MPA) OH- PO4 RemarksCompleted By SEPCTI DEC PLN JASERSignatureDate8.5 Steam Purging8.5.1 Purpose To ensure the safety and economy operation of the units, the inevitable welding slag, metal rust and other sundries in the boiler superheater and pipeline of steam system of newly assembled units shall be purged to the cleanest extent before the formal steam supply.8.5.2 Scope Boiler superheater system Steam pipeline connecting start-up boiler to auxiliary steam header8.5.3 Purging plan Purge the boiler superheater system by energy storage (pressure decrease) method. the Process: steam drum--> superheater--> main steam valve--> main steam pipeline--> temporary vent pipeline Purge steam pipeline connecting start-up boiler to auxiliary steam header and boiler superheater system simultaneously.8.5.4 Steam parameter for purging Open main steam valve when the drum pressure reached 0.5~0.6MPa. After fully open main control valve, drum pressure decreases to 0.4~0.5MPa. At that time, close main steam valve.8.5.5 Quality standard
  24. 24. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 24 of 44 According to the new "Technical Code for Erection and Acceptance of Electric Power Construction (1996 Edition)", while ensuring the purging factor larger than one, the purging work is qualified as the matter, maximum particle diameter on the target board no more than 0.5mm and number of macroscopic spot no more than 5, happens for twice continuously.8.5.6 Temporary devices (1) The temporary pipeline shall be connected in proper place before plant-service steam header and be led to safe place for steam exhausting with outlet directed to open space. Target board shall be installed in the suitable place near regular pipeline. In condition that the quality of purging is guaranteed, minimize the length of the pipe, elbows and joints to reduce the resistance for the system. (2) Temporary purging pipeline shall be equipped with solid and reliable supports and hangers and consider the thermal expansion of the pipeline and steam counterforce by purging. (3) Same-diameter short pipe shall be connected instead of main steam flow orifice plate until the purging work is finished.8.5.7 Precondition for ignition (1) Systems return to normal after boiling and cleanup of upper and lower drum and sub-header of water wall. (2) Main boiler and auxiliary equipments have been installed and insulated. Platform, handrail and boarding are complete. (3) All facilities which affect the expansion have been removed. (4) Sufficient illumination is around the boiler proper and auxiliary units. (5) Installation of water level meter in drum shall meet the requirements. The local water level meters are accurate and remote water level meters are regulated and can be put into use for purging. (6) Sundries shall be cleared up inside the furnace and funnel. (7) Water charging and supply system shall meet the requirement and be ready to use. (8) Purging control valve have been adjusted and temporary pipeline have been completed according to requirement. (9) In boiler house, discharge systems of washing water and overflow have been installed as per design requirements. (10) Dosing, sampling, blowdown systems have been installed as per design requirements. (11) Chemical water treatment system can guarantee to supply qualified demineralized water. (12) Purging field is tidy, road is clear, trench covers are complete, and scaffolding have been removed for convenient operation. Operating floor has been completed basically without any vulnerability such as voids etc. (13) The utilities system can guarantee the safety and stability of production, construction and commissioning. (14) Preparation work has been done for commissioning. Operators, trained and tested, are qualified. Operation specifications and system diagram have been approved. Operating tools are fully equipped and commissioning log is prepared.
  25. 25. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 25 of 44 (15) A sound commissioning management organization has been established, the responsibilities and liaison system have been clearly defined. Personnel for adjustment, maintenance and operation are on board. Commissioning measures have been approved and technical clarification has been performed. (16) Chemicals materials, chemical water and fuel oil for commissioning are ready. (17) Fire-fighting equipments and facilities in field shall meet the requirements. (18) The Installation Contractor, Operation Contractor, Owner, Supervisor, Contractor and Commissioning Contractor inspect the entire units thoroughly to confirm that the unit is ready for ignition. Problem found must be solved immediately, if any.8.5.8 Tests before ignition (1) The system valves and dampers for purging shall be inspected completely by operators to meet the following requirements: flexible operation; on-off direction accords with the indication; and remote panel conforms with local one. (2) Test for interlock protection8.5.9 Preparation before ignition (1) Start up water feed pump until the water level reaches about -30mm in the drum. (2) Preparation before ignition should been made as per specifications when receiving ignition signal. Notify the electric control room to feed the rotary machine, electric dampers and electrically operated steam and water valves to be used. Heating control room feeds the panels and instruments to be used. Put cooling water system into use. Ignition is implemented as per specifications.8.5.10 Purging process (1) Ignite and increase the pressure once receiving ignition signal. When the pressure reaches to 0.2MPa, steam pipeline should be warmed up. After that, trial purging is started and check if the system expansion and stress state are normal when the pressure is up to 0.3MPa. If normal, boost pressure continuously to 0.4MPa~0.5MPa for next purging until the target board is basically qualified. Then shut down and cool the boiler for 12hr and ignite the boiler and boost the pressure again to purge until the target board is qualified. (2) After purging, to boost pressure for leak test and safety valves adjustment or to shut down for system recovery is subject to the site conditions.8.5.11 Safety precaution and instruction (1) Keep combustion as stable as possible when purging. (2) The drum water level control to avoid severe water shortage or overfall is of the greatest significance during purging period. As the control valve opens, the steam pressure decreases sharply, which causes great rise of drum water level. Actually, it is false appearance, and the water supply shall be increased suitably rather than being decreased. For the reason that the drum water level
  26. 26. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 26 of 44 declines greatly even it is invisible when the control valve is closed, increase the water supply to maintain a visible level when closing the valve. When the water level starts to rise again, reduce the water supply promptly to avoid rising too high. To prevent steam from bearing lots of water, the drum water level shall be maintained around -50mm before opening the control valve in purging. (3) No flammable and explosive materials near purging pipeline. No people in area 20m around steam outlet. Set guard line and assign persons to be on duty. (4) Make sure that everyone has left before opening the control valve, especially when changing the target board. Person unrelated shall keep away from purging pipeline. (5) Pipeline shall be warmed up completely before purging. Trial purging, under the pressure 50%~75% of the regular pressure shall be conducted once or twice to inspect the conditions of support, expansion and leakage of the temporary system and learn the control method of water feed flow gradually. Steam trap on main steam pipeline shall be partially opened while the other is closed during normal purging work.. (6) A target board shall be put in the pipeline to check the dirtiness of pipeline and the reliability of board in the first purging. (7) All rotary machines shall be monitored by relevant personnel. (8) Operation should be conducted in a manner of unity of command. Shut down purging in case of emergency, and handle accident according to Accident Management Procedure. (9) The parts unable to be purged by steam shall be cleaned mechanically and manually. Safety measures shall be considered to prevent the dirt from recovered welding joint. (10) 20 pieces of target board, made of aluminum and polished, should be prepared. Target boar size: no less than 8% of the inner diameter of discharging pipeline in width; and equal to the inner diameter in length. Steam purging record format Open valve Close valve Date/time Target Drum Superheater Drum Superheater Superheater PRESS.(MPA ) outlet TEM. PRESS.(MPA ) outlet PRESS. outlet TEM. Yes/No (℃) ( MPA ) (℃)Completed By SEPCTI DEC PLN JASERSignature
  27. 27. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 27 of 44Date8.6 Steam Tightness Test8.6.1 Purpose: To guarantee the safety operation of the units in future, the steam tightness test, under the operating pressure at hot state, is to completely inspect the boilers heating surface, the steam & water pipeline, steam header, flanges. welded junction, expansion system and load-carrying capability, displacement and the extension of fixing apparatus or spring supports and hangers.8.6.2 Test Content: (1) Close the main motorized steam valve at the boiler outlet; the pressure boosting rate can be controlled by the adjustment of fuel oil pressure or the exhaust steam valve. When pressure rises to 1.29MPa and is at steady state, people specially assigned shall check the tightness of the boiler proper, auxiliary device and the steam and water pipelines involved. (2) Inspection the tightness of welded joints and flanges of the boiler. (3) Inspection tightness of all the steam and water valves of the boiler proper system. (4) For steam and water pipeline of the boiler, check its expansion condition, check whether the load-carrying capability, the displacement and the extension of its supports, hangers and spring hangers are normal, and check whether any barriers impact the expansion. Steam tightness test checklist contents Check result remarksInspection the tightness of welded joints and flanges of the boiler. □Yes □NoInspection tightness of all the steam and water valves of the boiler □Yes □Noproper system.For steam and water pipeline of the boiler, check its expansioncondition, check whether the load-carrying capability, the □Yes □Nodisplacement and the extension of its supports, hangers and springhangers are normal, and check whether any barriers impact theexpansion.Completed By SEPCTI DEC PLN JASERSignatureDate8.6.3 Testing conditions: (1) Purging has been completed.
  28. 28. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 28 of 44 (2) Areas inside and outside boiler is cleaned. Road is clear. (3) All inspection holes and manholes have been closed. (4) Tests and inspections before ignition have been completed.8.6.4 Test Procedure: (1) Timely adjust combustion intensity and open rate of steam trap. Control temperature and pressure rise rate according to Operation Specification. (2) Record expansion value at the following conditions: before and after water feed, 0.3–0.4Mpa, 1.0MPa, 1.25MPa. (3) Start steam tightness test when pressure of main steam rise to 1.25MPa.8.6.5 Safety Precautions: (1) Strictly control increasing rate of temperature and pressure to ensure sufficient expansion of each heating part of boiler proper. (2) Check the expansion state of each heated part in pressure boosting process. Report problems if found. Stop increasing temperature and pressure, if necessary, to take measures to eliminate a hidden danger. Then continue the process. (3) Operation should be conducted in a manner of unity of command. Strictly follow orders and prevent personal injury and damage to equipment. All operating personnel participating commissioning shall strictly follow Safety Regulations and related safety provisions at site, thus to ensure safe and reliable commissioning. (4) If equipment damage or personal injury may occur, stop works immediately and shut down the unit if necessary, and then analyze causes and take corrective measures; (5) During entire commissioning, personnel of various discplines shall be in place, thus to ensure equipment operation safety.8.7 Safety valve setting8.7.1 Purpose: Being the primary safety devices for the boiler, safety valves of drum and superheater shall be adjusted to act accurately and reliably before commissioning to ensure the safe operation of the boiler unit.8.7.2 Setting parameter: Refer to attached table.8.7.3 Preparation before tests (1) Safety valves have been installed and checked, which accords with installation requirements. (2) Standard pressure gauges, calibrated and provided by the installation contractor to adjust the safety valves on site, have been installed (0~6MPa per one, above grade 0.4). (3) Safety valves platform is clean. Road is clear. Illumination is sufficient. (4) Adjustment tools, communication tools and record lists are prepared.8.7.4 Setting procedure (1) Start steam discharge test when pressure rise to 0.8MPa-0.9MPa. Check the steam
  29. 29. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 29 of 44 discharge and action of safety valves. If no problems found, continue boosting pressure to the setting pressure needed for setting. The setting of safety valves is conducted before the setting of safety valve of superheater. (2) Decrease pressure after the setting of safety valves. Start the setting of safety valves on the superheater. (3) If the trial actuation of the safety valve is not qualified for the first time, decrease pressure and adjust it again. Then increase pressure to test the trial actuation until it is qualified.8.7.5 Safety Precautions: (1) During the adjustment of safety valve, operators and safety valve adjustors should act according to the unified command of commissioning personnel so as to ensure personal and equipment safety. . (2) Participants should keep their post according to work division and take records of operation, adjustment and check. (3) During the adjustment, enough platform and railings should be set around safety valves; illumination is sufficient. (4) Before setting, release the drum water level protection, in case the false level caused by take-off of safety valve starts the protective action of boiler. (5) During pressure boosting, assign people to check the tightness and expansion of boiler. Report and solve problems found to impact the increasing of pressure and temperature timely. (6) During the adjustment, operator is responsible to maintain the stable working state of unit, especially the stable pressure. At the moment the safety valves discharge steam, drum water level changes greatly. So, when adjusting the safety valves, drum water level should be lower than the normal level. Adjust the water supply to control the drum water level properly. (7) Decrease the pressure to 75% of the actuation pressure before adjusting the safety valves. Experienced operator with protection masks and heating-insulated gloves adjust the safety valves, and others should be kept away from the field. (8) During the adjustment, adjust the weight of safety valves on drums. Remove top cover of safety valves on superheater, unscrew or wind up spring to reach the set actuation pressure. Then tighten fastening screw, assemble the top cover and tighten the hexagon screw. (9) Do not hit any parts on the safety valve. Lift handle directly to open the safety valve. (10) After the adjustment of safety valve, all externally adjusted parts should be marked, fastened, sealed, recorded and certificated before put into operation. Attached List: The hot setting value record format of boiler safety valve Design value Actual setting valueName/Type Popping Press. Return Press. Popping Press. Return Press. Remarks (MPa) (MPa) (MPa) (MPa) Drum 1.43 1.33-1.37 4-7%Safety valve
  30. 30. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 30 of 44 A48Y-25Super heaterSafety valve 1.30 1.21-1.25 4-7% SA48Y-25Completed By SEPCTI DEC PLN JASERSignatureDate Remarks: Actuation value of safety valve is from the Manufacturers Information.8.8 Load commissioning8.8.1 Test purpose: Load commissioning is main process of unit commissioning. Concerning to the safety, quality and project period of unit commissioning, load commissioning is a comprehensive performance evaluation of the unit and complete check and inspection of the sub-system commissioning at the early stage.8.8.2 Conditions required before load commissioning (1) Drying and boiling out, steam purging, tightness test, safety valve setting of start-up boiler have been completed. (2) All temporary system used in sub system have been removed. (3) All defects found in the subsystem commissioning have been eliminated. (4) Chemical water system is complete to supply qualified demineralized water at any time. (5) Plant-service power system is complete to cut and supply power according to commissioning requirements at any time. (6) Illumination and communication system is complete to communicate at any time. Fire control equipments are equipped. (7) In commissioning field, road is clear, illumination is sufficient, emergency illumination is reliable. (8) Boiler chemical feed, sampling, blowdown and drainage, air vent system have been installed and insulated. (9) All steam and water valves and dampers for boiler have been installed and tested. On-site open rate is the same as that shown in center control room. (10) Confirm that the following systems have been installed and can be put into operation. Boiler air and flue gas system; Water feed system;
  31. 31. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 31 of 44 Fuel oil system; Industry water system; Chemical sampling system; Drainage system; Water supply, drainage and fire control system; Main steam system and its desuperheating water (10) All on-site instruments and instruments on operation platform and panels have been installed and calibrated, and can be put into use. (11) All interlock protection loop has been installed. After static test, all interlock, protection and alarm value have been set according to requirements. Visual and audio system has been adjusted. (12) Boiler expansion indicator has been installed according to design requirements. Expansion barriers have been eliminated and expansion indicator has been regulated to zero. (13) Observation holes, manhole door and inspection holes have been closed. Explosion door is complete. (14) Prepare sufficient fuel oil for commissioning. (15) Prepare sufficient chemical water and chemicals. (16) Production preparation has been made. Operators passing training are on duty. (17) Organization is complete and job division is clear. (18) Constructor organizes maintenance team and prepare materials and tools for maintenance. (19) Operation measures should be approved and clarified under the direction of commissioning command party. Commissioning, operation, maintenance personnel is on duty. (20) Marks of equipment and main pipeline are complete and meet requirements. Tags on system equipment and valves are complete. (21) Auxiliary header on the steam supply side has been installed and insulated and are ready for steam.8.8.3 Commissioning period (1) Non-load period After the commissioning of all subsystem of start-up boiler, restore the temporary system and steam can be sent to auxiliary header. The warm-up of pipeline before supplying steam to the auxiliary header is the non-load commissioning. (2) Load period After the start-up boiler supplies steam to the auxiliary header, adjust the burning capacity according to steam consumption of users, and adjust the boiler load to keep pressure steady.8.8.4 Commissioning Procedure
  32. 32. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV BCommissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 32 of 44 (1) Non-load procedure 1) Water feed Water feed time: winter≥2 hrs; summer≥1 hrs. Feed water temperature <40℃. Before feeding water, close blowdown valves and open air vent and exhaust steam valve to release air in boiler. Start water feed pump to inject soft water to the boiler through economizer. Stop water feed pump when the water level is higher than the low alarm. After the level is stable, check whether the level decreases. If so, check and deal with it. 2) Work before ignition: check the conditions required 3) Ignition of boiler. Boiler sequence start: boiler startup instruction give out ,start FDF, set ventilation tunnel. automatically open inlet air damper of FDF to more than 70% position, the furnace pressure is about 1000--5000Pa. program automatically start purging furnace for 1 min. program automatically close damper to 20% position. Program automatically give out light instruction. details: first, high power ignitor automatically light, then automatically light up small gas gun ;after about 3s, automatically light big oil gun and automatically open oil 4 feed/return valves. after 5s, automatically stop small gas gun. the flame detector detect flame and exist, mean the startup process is success. If not, after 5s,flame detector is no flame, boiler startup process is failure. 4) Pressure boosting After ignition, adjust the oil pressure of oil gun according to temperature and pressure rise curve for cold start-up. Increase pressure and temperature of boiler. At the early stage of pressure boosting, adopt low burning. When boosting the pressure, temperature can not rise too fast to avoid overlarge heat stress caused by uneven heating. After the pressure rises, watch the level in boiler. Level rises because of heating. If it exceeds the highest level, start blowdown. When saturated vapour is generated in the drum or drum pressure reaches 0.1MPa, increase combustion, close exhaust steam valve and flush water level meter and elbow of pressure gauge at the same time. When drum pressure rise to 0.1MPa, close corresponding air vent. Drum pressure rises to 0.2--0.4MPa and operation is steady. Check whether the boiler is abnormal. Ask installation contractor to tighten screws in hot state. Ask heating engineering team to flush instrument pipe and regulate the level meter. Ask the chemical team to flush the sample tube. When pressure increases gradually, note whether each part makes special sound. If so, check the state immediately. Shut down furnace to check, if necessary. Start operation after lifting failure. Continue boosting pressure. When drum pressure reaches the required value, stop
  33. 33. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV BCommissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 33 of 44 burning. Open the valve of superheat steam outlet to put water feed system into operation, adjust combustion, open desuperheating water, and supply steam formally. Continuous bolwdown should be carried out during steam supply. 5) Formal steam supply When steam pressure reaches working pressure 1.25MPa, supply steam. Before supplying steam, maintain low drum water level, sufficient pipeline warm-up and steady combustion in furnace, Desuperheating water is used to adjust the temperature of superheat steam. When the temperature of superheater steam is higher than the required value, increase the desuperheat water to decrease the temperature of superheat steam by motorized control valve of desuperheating system. When the temperature of superheater steam is lower than the required value, decrease the desuperheat water to increase the temperature of superheat steam. Adjust the temperature of superheat steam within 345±5℃. (2) Load period 1) Adjust the burning capacity according to steam consumption of users and fuel oil pressure. Maintain steady pressure, combustion, water level of boiler. Keep steam temperature within regulated scope. The oil temperance and pressure meet the requirements. 2) Start thermal adjustment of automatic control system at proper time, according to load of boiler. Automatic adjustment of drum level Automatic adjustment of combustion(steam pressure) Automatic adjustment of desuperheating water(superheater outlet temperature) (3) Normal operation and maintenance When boiler is in operation, continue feeding water to keep water level within normal scope. Water level meter should be flushed at least once each shift. Note the combustion state frequently. Maintain reasonable air distribution for good combustion. Keep the furnace pressure between1000—5000Pa Supervise and maintain the pressure and temperature of overheat steam, and make it within normal scope。 Note the boiler proper and gas and air flue, and make pressure, gas temperature and wall temperature of them within normal scope. Check the reliability of valve action frequently. Patrol equipment and system frequently. Report or handle with abnormal situation, if found. Supervise the quality of feed boiler water. Periodical and continuous blowdown should be executed after receiving the notification of chemical team. Operator should take records of boiler operation parameter hourly。 (4) Normal shut down
  34. 34. PLTU 1 Jatim-Pacitan(2×315MW) Project Procedure of Start-up Boiler REV B Commissioning Procedure SCCTI-TS-GL-CS-006-2009A Page 34 of 44 Reduce fuel and corresponding air volume gradually to weaken the boiler capacity. With the decreasing of the load, reduce water to maintain normal level in drum。 When the steam supply is cut off, close the boiler outlet motorized valve. If the pressure continues boosting, steam release and water fed should be strengthened. After pressing the shut down button, the burner will turn off oil-gas solenoid valve automatically. After five minutes, blow the furnace, and the boiler will shut down automatically. After flameout, check and close flue baffle and manual valves of fuel oil system. Stop the oil pump. Stop water feed pump when water is stopped. Before the drum pressure decreases to the atmosphere, temperature of flue gas and air system and auxiliary device must be supervised continuously. (5) Occasions for Emergency Shut Down Pressure over the specified value Low low water level in drum, and level cant be observed Water supply device malfunction, fail to feed normally All level meters malfunction All safety valve malfunction Cracks on boiler, blurts of water wall tube, overheat steam pipe and economizer pipe burst and damage of boiler wall threats the safe operation of boiler severely8.8.5 Complete trial operation record: For main parameter in trial operation, see the Appendix 2.9. Safety Measures9.1 Safety rules for commissioning9.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant safety rules, wear reasonable clothing and appropriate personal protective equipments.9.1.2 In case of any accident that damages the equipment or hurts person happened or possibly happen during commissioning, suspend commissioning immediately and put the equipment to the lowest energy state. Then investigate the cause and take corrective measures.9.1.3 The parties participating in the commissioning shall obey the command of commissioning personnel. In case there is an emergency endangering personal or equipment safety, any person has the right to stop the operating equipment immediately and report to the control room.9.1.4 All professional staffs shall be on respective duties during the whole commissioning to guarantee the safe operation of equipments.9.2 Personal Risk and Preventative Measures Rotary machine In adjustment or test, people may be injured by the rotary machine. So, work carefully to avoid touching the rotary parts with hands or tools. Misapplication or non-wearing of helmet

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