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7/28/2019 AUX BLR FAN
1/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0032
NTPC Ref no SIM/1/TS/2/32Sheet 1 of 9
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)
SLNO
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
PLANT DETAILS
OBJECTIVE
PROPOSAL
SERVICES REQUIRED
SAFETY PERECAUTIONS
EMERGENCY PROCEDURE
STAE OF THE PLANT
TEST METHOD
COMPLETION CRITERIA
APPENDICES
a. LOG SHEET
7/28/2019 AUX BLR FAN
2/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0032
NTPC Ref no SIM/1/TS/2/32Sheet 2 of 9
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)
SLNO
1.0
2.0
3.0
4.0
5.0
6.0
PLANT DETAIL:
Refer to procedure for commissioning of Auxiliary Boiler.
OBJECTIVE:
To commission a) Forced Draft Fan andb) Boiler Feed Pump of auxiliary Boiler.
PROPOSALS:
It is proposed to commission the auxiliaries by conducting trialrun for 8 Hrs at low load condition.
SERVICES REQUIRED:
Availability of L.T Power supply.
Availability of lighting, communication facility around theauxiliaries area.
Availability of sufficient quantity of DM water.
Availability of Service and Instrument air
Availability of cooling water.
SAFETY PRECAUTIONS:
Refer Procedure No.PS-DC-186-500-100/SIM/1/TS/2/100
EMERGENCY PREPARDNESS:
Refer Procedure No.PS-DC-186-500-100/SIM/1/TS/2/100
STATUS
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
3/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0032
NTPC Ref no SIM/1/TS/2/32Sheet 3 of 9
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)
7/28/2019 AUX BLR FAN
4/20
SLNO
7.0
7.1
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.1.6
7.1.7
7.1.8
7.1.9
STATE OF THE PLANT:
FORCED DRAFT FAN
Erection of Fan and Motor completed as per recommendeddrawing and check lists.
Erection of the auxiliary boiler completed including ducts from fandischarge up to chimney completed.
All permanent supports are erected as per drawing for bothpressure parts & non-pressure part.
Suction cum Requlating damper and discharge dampers are
erected and are freely operating.
Fan bearings are lubricated as per recommended lubricationschedule.
All debris and temporary supports inside the fumace and ductsare removed.
Electrical connection to FD Fan Motor is completed withrecommended protections and the required mock start / stopconducted satisfactorily under Fan and Motor in decoupled
condition.
Insulation Resistance of the motor measured and confirmed OK.
All local and remote instrumentation of the Fan are made ready(List of Indication, Interlock & protection required made mutuallyby BHEL & NTPC)
STATUS
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
5/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0032
NTPC Ref no SIM/1/TS/2/32Sheet 4 of 9
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)
SLNO
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
7.2.8
7.2.9
BOILER FEED PUMP:
Erection of Pump and Motor completed as per recommendeddrawing and checklist.
Erection of Feed water system from Deaerator Feed storagetank, Suction pipe line, discharge pipe line up to Boilercompleted.
All permanent supports of the Feed Water System are erected asper drawing.
Pump bearings are lubricated as per recommended lubricationschedule.
Feed storage tank is cleared off debris.
Electrical connections to BFP Motor is completed withrecommended protections and the required mock start / stopconducted salisjactorily under pump and motor in decompled
condition.
Insulation Resistance of the motor measured and confirmed OK.
All local and remote instrumentation of the pump are made ready.(List of indications, interlocks and protection required mademutually by BHEL and NTPC).
CW lines are connected to pump (If applicable)
STATUS
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
6/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0032
NTPC Ref no SIM/1/TS/2/32Sheet 5 of 9
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)SLNO
8.0
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.2
8.2.1
8.2.2
8.2.3
METHOD:
A) FD FAN:
Under decompleted condition, start the motor and checkdirection of rotation.
Motor started and 8 Hrs trial run completed. During the trial run,
observation made for normal vibration and bearing temperatures.
Fan and Motor are compled and Air & flue gas ducts are lined upfor fan running.
Fan started keeping the suction cum regulating damper inminimum and discharge damper in closed condition.
Loading of the fan gradually raised to around 20-30% and 8 Hrstrial run carried out. During the trial run, Fan Vibration, loadcurrent, bearing temperatures and furnace pressure are logged.
B) BFP:
Under decoupled condition, start the motor and check direction ofrotation.
Motor started and 8 Hrs trial run completed. During the trial run,observations are made for normal vibration and bearingtemperatures.
Pump and motor coupled and Feed water system from Deaerator
Feed storage Tank to pump ready with RC line open anddischarge valve closed.
STATUS
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
7/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0032
NTPC Ref no SIM/1/TS/2/32Sheet 6 of 9
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)SLNO
8.2.4
8.2.5
Pump started and put for 8 Hrs trial run through re-circulation line.
During the trial run, pump vibration, local current, bearingtemperatures, suction and discharge pressures are logged.
STATUS
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
8/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0032
NTPC Ref no SIM/1/TS/2/32Sheet 7 of 9
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)SLNO
9.0
9.1
9.2
COMPLETION CRITERIA:
FD Fan run for 8 Hrs trial run satisfactorily.
BFP run for 8 Hrs trial run satisfactorily.
STATUS
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
9/20
SHEET 8 OF 9
10.0 LOG SHEET
DATE:
STATION :UNIT NO :ACTIVITY : TRIAL RUN OF FD FAN
S.NO.FAN LOADING DISCHARGE
PRESSUREFUMACE
PRESSURE
BEARINGTEMPERATOR
IGV AMPS DE NDE
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
10/20
SHEET 9 OF 9
10.0 LOG SHEET
DATE:
STATION :UNIT NO :ACTIVITY : TRIAL RUN OF BFP
S.NOPUMP
LOADING
AMPS
PRESSUREBEARING
TEMPERATURE
SUCTION DISCHARGE DE NDE
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
11/20
PROCEDURE FOR COMMISSIONING OF
AUXILIARY BOILER (FD FAN & BFP)
7/28/2019 AUX BLR FAN
12/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152
NTPC Ref no SIM/0/TS/4/152Sheet 01 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM
SLNO
1.0 PLANT DETAILS:
Oil Handling System forms a part of fuel oil plant. Refer totesting schedule No.PS-DC-186-500-0008/(SIM/1/TS/1/007)
The plant details of the oil handling system is given in section 1.0of above referred testing schedule.
Technical Specifications of Drain oil System
Drain oil System
No. of Pumps : 1Capacity : 10 Cu.M./HrType : Vertical, Single Screw.Tank : 10 Cu.M
Oil Water Separator System
No.of Pumps : 2 Nos, of Oil Recovery Pumpsand 2 Nos.of Sump Pumps.Capacity : 10 Cu.M/Hr for ORP & 30 Cu.M / Hr
For Sump Pump.
STATUS
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
13/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152
NTPC Ref no SIM/0/TS/4/152Sheet 2 0f 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM
SLNO
2.0
3.0
3.1
3.1.1
3.1.2
3.13
3.1.4
3.1.5
3.2
OBJECTIVE
To clean and commission the LFO & HFO handling systemincluding the pressurizing pumps and make it available for mainunit commissioning and operation .
PROPOSAL
Following proposals will be followed to achieve the objective
Cleaning of LFO Handling system.This is further divided into
LFO Receiving Terminal (Cleaning by Compressed air at 4-5KSC)
Piping from LFO terminal to suction of LFO Handling Pump.
LFO Handling Pump discharge to inlet points of LFO Day tankand LFO storage tank.
Sl.No.3.13 and 3.14 are cleaned by card board bursting methodas described in section 8.0
Cleaning of HFO handling SystemRefer to Testing Schedule PS-DC-186-500-0008 /(SIM /1/ TS/1/007)
STATUS
Signatures
7/28/2019 AUX BLR FAN
14/20
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152
NTPC Ref no SIM/0/TS/4/152Sheet 3 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEMSLNO
3.3
4.0
5.0
6.0
7.0
7.1
Commissioning of all pumpsa) Unloading Pumps of LFO / HFO
System Trial run for 2 Hrsb) Pressurizing Pumps of LFO / HFO
System Trial run for 8 Hrsc) Pumps of Drain Oil System
Trial Run for 1 / Hrs (By local recirculation)
SERVICES REQUIRED
SAFETY PRECAUTIONS
EMERGENCY PRECAUTIONSFor Sections 4.0, 5.0 & 6.0, refer to the corresponding sectionsof the following procedures.
a) PS-DC-186-500-151 / (SIM / 1 / TS / 4 / 151)
b) PS-DC- 186- 500 - 0008 / (SIM / 1 /TS / 1 / 007)
STATE OF THE PLANT
Hydraulic Test, Support work and Insulation of the following linesare completed.
1. LFO / HFO unloading heoder2. Line from LFO / HFO unloading heoder to LFO / HFO
unloading Pumps3. Line from LFO / HFO unloading pumps to LFO / HFO
storage and
Day Tanks.4. LFO / HFO Storage and Day Tanks to LFO / HFOpressurizing pumps and their respective RC lines
5. Drain oil and oil water Separator system.
STATUS
Signatures
7/28/2019 AUX BLR FAN
15/20
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152
NTPC Ref no SIM/0/TS/4/152Sheet 4 of 7
Plant area: OFF SITEPROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM
SLNO
7.2
7.3
7.4
7.5
7.6
7.7
7.8
Erection of the following completed as per recommendeddrawing.
1. LFO /HFO unloading Pumps.
2. LFO / HFO pressurizing pumps.
3. Pumps of Drain oil and Oil water Seperator system
4. LFO / HFO storage and Day tanks.
Auxiliary Boiler is fully ready for supplying Steam
Trip valves, Control Valves are not erected and suitable spoolpieces are erected at these places
Filter elements and NRV internals removed.
Temporary exhaust pipe lines for steam blowing erectedwherever required, avoiding machinery and Buildings.
All vents and drains are properly routed and supported.
Local level indicators of LFO / HFO storage and Day tanks aremade available.
STATUS
Signatures
7/28/2019 AUX BLR FAN
16/20
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152
NTPC Ref no SIM/0/TS/4/152Sheet 5 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEMSLNO
7.9
7.10
7.11
7.12
8.0
8.1
8.1.1
8.1.2
8.1.3
8.2
8.2.1
Road and rail approach to the Oil handling area is complete tofacilitate LFO / HFO unloading.
All steam lines as well as HFO lines are insulated.
No permanent Instruments are erected in lines being steamblown. They are isolated incase erected.
All electrical systems required for pump commissioning are madeavailable.
METHOD
LFO Handling System.
LFO receiving Terminal is cleaned by compressed air blowing ata pressure of 4 5 kg / cm. Air admitted at a suitable inlet pointand blown one by one through other openings.
Sl.No.3.1.3 and 3.1.4 are cleaned by card board bursting methodby providing a card board at a suitable location and pressurizingthe line to 3 4 KSC. The card board bursts and effects cleaningof the pipe line.
Air inlet point and location for putting card board to be decided atsite.
HFO Handling system
Refer to Testing Schedule PS DC 186 500 0008(SIM / 1 / TS / 1 / 007)
STATUS
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
17/20
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152NTPC Ref no SIM/0/TS/4/152
Sheet 06 0f 07
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM
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SLNO
8.3
8.3.1
8.3.2
8.3.3
8.4
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.4.6
STORAGE AND DAY TANKS
Hydraulic fill test of Storage and Day Tanks of LFO / HFO systemare completed as per suppliers recommandation.
After satisfactory hydraulic fill test, water drained and tanks areallowed for drying.
The tanks are manually cleaned thoroughly and manhole doorsboxed up before pumping LFO / HFO oil into the tanks.
COMMISSIONING OF PUMPS
Insulation value of the motor measured and ascertained that thevalves are satisfactory.
Motor bumped and ensured correct direction of rotation.
All the motors are trial run for 2 Hrs and during the trial run, motornoload current noted down.
After coupling the motor with pump, oil lines are slowly charged /vented / drained to the required amount and the pumps areprimed sufficiently.
Pump started and put on trial run under recirculation duration asgiven in section 3.3. During trial run, load current of the pumpnoted.
All the leaks observed during charging and filling up of unloadingterminal Header, oil lines, storage and day tanks are attendedexpediously.
STATUS
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152
NTPC Ref no SIM/0/TS/4/152Sheet 07 of 07
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM
7/28/2019 AUX BLR FAN
19/20
SLNO
9.0
10.0
COMPLETION CRITERIA
Cleaning and commissioning of LFO / HFO Handling system
including pressurizing pump completed by following the proposalsas given in section 3.0
a) Drawings referred are
i) PE DG 186 166 0001 ( P & ID for FO System)ii) PE DG 186 166 0003 ( P & ID for LDO System)
STATUS
Signatures
NTPC BHEL
7/28/2019 AUX BLR FAN
20/20
PROCEDURE FOR COMMISSIONING OF OILHANDLING SYSTEM