Ball Cleaning System

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Commissioning Measures Form for Approval

No.YDTD-TS09

Project

name

Phase I of 2330MW Project of Tengda

Coal-fired Power Plant in India

Contract

No.

To: Tengda Project Department of Sichuan Machinery & Equipment Import & Export Corporation

Now it is submitted for the examination and approval with the rubber ball cleaning system commissioning

measure

Document No. : QJCS-9

Appendix: rubber ball cleaning system commissioning measure

Contractor: Sichuan Tongneng Power Technology Co. Ltd.

Project principal Date


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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in IndiaRubber ball cleaning system commissioning measure

Examination and approval opinions of the project supervision department:

Project supervision department (seal)

Supervision engineer: Date

Chief supervision engineer: Date

Examination and approval opinions of the owner

Legal person of the project (seal):

Owner representative Date

Contractor: Sichuan Tongneng Power Technology Co. Ltd Mar. 2008


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Examination and Approval Record for

Documents

D o c u m e n t

n a m erubber ball cleaning system commissioning measure

D o c u m e n t

N o .YDTD-QJCS-09

The 1st

version

Date of

publication

The

2nd

version

Date of

publication

Main revised content

E d i t i o n n o .

The 3rd

version

Date of

publication

Main revised content

M a n a g e r s

a p p r o v a l o f

t h e

c o m m i s s i o n i

n g p r o j e c t

D a t e :


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Content

1. Compilation purpose 3

2. Compilation reference 3

3. Quality standards and objective of commissioning 3

4. Responsibility division 4

5. System brief introduction 5

6. Conditions prior to commissioning 6

7. Working procedure of commissioning 6

8. Commissioning steps 6

9. Safety Precautions 11

10. Appendix 13


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1 Compilation purpose

1.1 These measures are worked out for guiding and standardizing the commissioning work of

system and equipment, and ensuring that the system and equipment can be used safely and

normally.

1.2 Check electric, thermal protection interlock and signal devices of rubber ball cleaning

system to confirm that they can run reliably.

1.3 Check the operation situation of the system and equipments and performance of the system

to find and eliminate the possible defects.

2. Compilation reference

2.1 Specifications for Start-up and As-built Acceptance of Capital Construction Engineering

of Thermal Power Plant (1996 Edition) DJ[1996] No. 159)

2.2 The Codes of Erection and Acceptance of Electric Power Construction (Section of

Steam Turbine Unit) DL50111992

2.3 The Codes of Erection and Acceptance of Electric Power Construction (Section of)

DL50311994

2.4 Standard for Quality Inspection and Evaluation of Thermal Power Engineering

Adjustment and Commissioning (JZ [1996] No.111)

2.5 Regulations for Start-up and Commissioning of Thermal Power Engineering (JZ [1996]

No.40)

2.6 Drawings, Installation and Operation Instructions, Warranty and Certificate of

Merchandise of manufacturer

2.7 Design documents, drawings and instructions, related documents, meeting minutes, etc. of

commissioning

2.8 Equipment supply agreement and international and national standards specified in the

supply agreement.

3. Quality standards and objective of commissioning

3.1 The commissioning should be in accordance with all quality standards and requirements of

relevant rubber ball cleaning system and equipments specified in the Standard for Quality


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Inspection and Evaluation of Thermal Power Engineering Adjustment and

Commissioning (1996 Edition), and the quality requirements specified in commissioning

contract, and satisfy the requirements of complete set start-up of unit.

3.2 The professional commissioning personnel and group leader should inspect and control the

key links of commissioning quality according to Appendix 1 (Quality Control Point of

Commissioning). For the problems found during commissioning, they should report to the

superiors in time so as to solve them and ensure that the start-up commissioning work can

go on smoothly.

4. Responsibility division

According to related provisions specified in the Regulations for Start-up and Commissioning ofThermal Power Engineering and commissiong contract, the duty of each party is as follows:

4.1 Installation unit:

4.1.1 Be responsible for the commissioning and trial run works of individual sectors of the

equipment.

4.1.2 Be responsible for insulation work of the system.

4.1.3 Be responsible for the examination, repairing, maintenance and defects eliminating works

of the commissioning equipments. 4.1.4 Prepare necessary examination and repairing tools and materials.

4.1.5 Coordinate with commissioning unit to carry out the commissioning work of

sub-systems.

4.1.6 Be responsible for the certificate issuing works after commissioning of this system in

divided parts.

4.2 Manufacturing unit:

4.2.1 Be responsible for the starting and stopping of equipments, operation adjustment andfailure handling during commissioning.

4.2.2 Be responsible for the formal label-hung works of the related system and equipments.

4.2.3 Prepare the operation regulations, tools, record forms, etc.

4.2.4 Be responsible for the inspection and normal maintenance works of equipments during

commissioning.

4.3 Commissioning unit:

4.3.1 Be responsible for the compilation works of commissioning measures (scheme) and


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confide technical disclosure.

4.3.2 Prepare related instruments, meters and tools used in the test.

4.3.3 Be responsible for commanding works on commissioning of sub-systems.

4.3.4

Be responsible for the recording and analyzing works of testing data. 4.3.5 Fill in the commissioning quality inspection and evaluation table

4.3.6 Be responsible for the acceptance and certificate issuing works of sub-systems after

commissioning.

4.3.7 Write commissioning reports.

4.4 The installation unit is responsible for while the commissioning unit participates in the

commissioning works of individual sector of pump sets. The commissioning unit is

responsible for the sub-system commissioning of the pump sets coordination withinstallation unit and other related units. The commissioning of rubber ball cleaning system

should be carried out under the unified command of trial run team and implemented under

the duty of the professional team, coordinating with leads in turbine profession, electric,

thermal control and other related professions.

5 System brief introduction

The both sides of turbine condenser of Tengda Coal-fired power plant in India have one setrubber ball cleaning device which is constituted of ball collecting screen, rubber ball pump, ballloading chamber and other components. Passing through rubber ball pump, the rubber ball is

brought out from ball loading chamber by the circulation water, and then runs into the inletcirculation water of A condenser, and runs to rubber ball pump from circulation water by the ballcollecting screen on outlet circulation water pipe of B condenser at last, repeatedly circulatinglike this. Specification of equipments

5.1 Rubber ball pump:

Type: WX-JQ-100

Flow: 100m 3/h (27.8L/s)

Head: 25m

Shaft power: 10.4KW

Net positive suction head: 1.6m

Speed: 1460r/min

Efficiency: 60%

5.2 Motor

Manufacturer: ABB MOTORS


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Type: QA162301-ADA

Power: 11KW

6. Conditions prior to commissioning

Before system commissioning, the commissioning personnel should have a comprehensive

examination on the requirements for this system commissioning in accordance with the contents

listed in Appendix 2 (Checklist for requirements of commissioning), and keep a record.

7. Working procedure of commissioning

The commissing work of rubber ball cleaning system can be carried out in accordance with the

following flow:

Technical disclosure of commissioning conditions needed to be confirmed before

commissioning interlock protection and alarm tests qualified trial run of rubber ball

pump use of system and dynamic adjustment

8. Commissioning steps

8.1 Inspection on actuator

8.1.1 Check and accept the electric switching throttle , and record the following data:

a. KKS code

b. Name (if the power plant has specific description on throttle , then take this description as

standard)

c. The indication of the on-the-spot position is correct or not

d. The operation direction on the electric panel and the feedback are correct or not

e.

The operation direction on the computer and the feedback are correct or not f. Open/Close time of the valve

8.1.2 Check and accept the ball collecting screen , and record the following data:

a. KKS code

b. Name (if the power plant has specific description on throttle , then take this description as

standard)

c. The indication of the on-the-spot position is correct or not

d.

The operation direction on the electric panel and the feedback are correct or not


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e. Open/Close time

8.2 Trial run of rubber ball pump

8.2.1 The idle run test of motor of rubber ball pump

8.2.1.1

Confirm that the installation work of motor is over. 8.2.1.2 Confirm that the driving power of motor is off, the motor insulation is qualified

8.2.1.3 Confirm that coupling between motor and primary air fan has been uncoupled, fill the

bearing of motor with needed lubricant.

8.2.1.4 Rotate the motor rotor, confirm that dynamic and static parts have no friction and

bearing has no abnormal sound;

8.2.1.5 Confirm that program controlling test of motor of rubber ball pump is qualified.

8.2.2

Inching of motor 8.2.2.1 Switch on the driving power and operation power of motor.

8.2.2.2 Start up the motor on MCC panel, do not press emergency button to stop motor on the

spot until the motor current falls back, notice that there is abnormal sound or not in

rotation, and record the following data:

a. Voltage

b. Start-up current

8.2.2.3 The rotation direction of motor should conform to the specified requirements ofmanufacturer and design.

8.2.3 Trial run of the motor

8.2.3.1 After 20 minutes, restart the motor on MCC panel. Notice that the start-up time

intervals do not less than that required by manufacturer or electric regulations, the

rotation has no abnormal sound or not, and record the following data:

a. Start-up current

b. Current in motion c. Bearing vibration

d. Bearing temperature

8.2.3.2 After 4-hour trial run, stop the motor on MCC panel and record the end time.

8.2.3.3 Switch off the driving power of motor.

8.2.4 Trial run of rubber ball pump

8.2.4.1 Check and confirm that the following conditions can be satisfied before trial run:

a. Confirm that each device, pipelines, electric connections, etc. conform to the


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requirements.

b. Wash the inlet pipelines of rubber ball pump by circulation water in trial run, and

reconnect the pipelines after washing.

c. The trial run of individual sector of rubber ball pump motor is over, and the coupling ofmotor and rubber ball pump are restored normal;

d. Confirm that the rubber ball cleaning system have been installed and the system is

complete;

e. Put the meters of system into use;

f. The valve state of pipeline of rubber ball pump conforms to the requirements of trial run.

g. Each bearing of rubber ball pump has sufficient lubricant and cooling water.

h. Check that the compression of stuffing should not be too tight and loose, and the stuffinggland should be compressed even.

i. Manually rotate the rotor of rubber ball pump, and the results indicate that the rotation is

normal.

j. The insulation resistance of motor of electric valve has been measured, and conforms to

the requirements. The power has been switched on

8.2.4.2 Confirm the following start-up condition for the last time:

a. The oil level of bearing is normal;

b. Confirm that the water level of circulation water basin is normal and the circulating

pump has been started;

c. Close all drain valves of pump sets, ball loading chamber and pipes;

d. Open the outlet valve of rubber ball pump, fill ball loading chamber with water and do

not close the extraction valve of ball loading chamber until it was filled with water.

Close the outlet valve of rubber ball pump when finishing the water injection.

8.2.4.3 Switch on the driving power of the pump, and stop it for checking following items

after starting for 5 seconds:

e. The rotation direction of the pump conforms to the design requirements or not

f. Have abnormal sound or not

g. The oil level and temperature of bearing is normal; the oil temperature is normal and not

higher than the fixed value specified by the manufacturer. The used lubricating oil is 65

70 , and the grease should not exceed 80

h. Check the vibration is normal or not; the vertical, horizontal and axial vibration of bearing measured

by qualified vibrometer should not exceed the following specifications in the situation of no load and


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full loads.

Vibration amplitude (mm)

Excellent Good Qualified

0.04 0.06 0.08

i. Check that the water pipes of the system have leakage or not 8.2.4.4 If have no abnormal phenomenon, restart the pump, open the outlet valves of rubber

ball pump and ball loading chamber, and then record the following parameters:

a. Start-up time

b. Start-up current

c. Current in motion

d. Bearing temperature

e. Vibration

f. Inlet pressure

g. Outlet pressure

8.2.4.5 Check the system has leakage or not.

8.2.4.6 The rubber ball pump keeps 8-hour trial run. After trial run, stop it and record its end

time and idle time.

8.2.4.7 Switch off the driving power of rubber ball pump.

8.3 The use of rubber ball cleaning system

8.3.1 The conditions before use

8.3.1.1 The circulation water system works normally.

8.3.1.2 The ball collecting screen has been placed at the position of operation.

8.3.1.3 Rotate the rotor of rubber ball pump, confirm that it is flexible without friction.

8.3.1.4 Check that the inlet and outlet valve of rubber ball pump can be closed normally.

8.3.1.5 Put the desired rubber balls into rubber ball chamber, place the changeover valve at

washing position, close the drain valve and fully open the extraction valve. The

rubber balls should meet the following requirements:

a. The rubber ball should be wear-resistant, soft and elastic with same-sized and through

holes, the specific gravity in wet state is 1.0 1.15.During the period of use, the

diameter of the rubber ball swells in standard scope without aging in the 5 45 water.

b. The diameter of rubber ball in wet state is 1.0 2.0mm bigger than internal diameter of

comparatively small cooling pipe.


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c. The used rubber balls should be 7% 13% cooling pipe of single flow of condenser in

normal operation. Put in 200 rubber balls at each side when doing the test of ball

recovery rate.

d. Immerse the rubber balls in water for 24 hours before use. 8.3.1.6 Do not switch on the power until the insulation of motor side of rubber ball pump is

qualified.

8.3.1.7 Check that the power of Programmable Logic Controller (PLC) has been switched on

or not and the indicator light of simulation display screen is normal or not.

8.3.1.8 This cleaning device is automatically controlled by Programmable Logic Controller

(PLC), the modification of program can change the automatic cleaning time.

8.3.2 The use of rubber ball cleaning device (Automatically start up and confirm the followingitems by PLC)

8.3.2.1 Switch on the rubber ball cleaning system.

8.3.2.2 Open the outlet valve of rubber ball pump, fill ball loading chamber with water and

do not close the extraction valve of ball loading chamber until it was filled with water.

Close the outlet valve of rubber ball pump when finishing the water injection.

8.3.2.3 Open the rubber ball pump and check that the rubber ball pump works normally or

not.

8.3.2.4 Open the outlet valve of rubber ball pump and ball loading chamber.

8.3.2.5 Monitor the operating situation of rubber ball by transparent window, check it to be

normal if there are rubber balls constantly returning after several minutes, about 30

min for one time cleaning.

8.3.2.6 Do the check test of ball recovery rate of rubber balls: Check the percentage that

returned rubber balls relative to the used rubber balls after finishing the cleaning.

8.3.3 The stop of rubber ball cleaning device (Automatically start up and confirm the following

items by PLC)

8.3.3.1 Place the changeover valve at ball collecting position after cleaning, and collect balls

for 30min.

8.3.3.2 Close the outlet valve of rubber ball pump, stop the rubber ball pump and close the

inlet valve of rubber ball pump.

8.3.3.3 Close the outlet valve of ball loading chamber.

8.3.3.4 Open the extraction valve and drain valve of ball loading chamber, check the amount

of rubber balls and record the ball recovery rate, cleaning time, etc. after draining the


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water.

8.3.4 Dynamic adjustment of the system

During the operation of rubber ball cleaning system, strengthen the supervision of each device in

the system, and adjust any abnormal situation immediately, so as to guarantee the system reach

its best operation.

a. Pressure adjustment

b. Temperature adjustment

c. Current adjustment

8.3.5 Fill in the trial run record

The main parameters in trial run should be recorded in Appendix5.

9. Safety Precautions

9.1 All personnel participated in the commissioning should strictly implement the Codes for

Safety Operation and related safety regulations on job site so as to ensure the

commissioning work can go on safely and reliably.

9.2 The commissioning works should be stopped immediately if person or equipment is

possibly endangered or has been endangered during commissioning. Find out and analyze

the reasons, and then submit the solutions.

9.3 The abnormal conditions found during the process of commissioning should be adjusted in

time and reported to the commanding personnel immediately.

9.4 The professional personnel of each field should be on guard during the whole process of

commissioning so as to ensure the operation safety of equipments.

9.5 If the operating pump in vaporization, equipment or pipes occur strong vibration and

parameters of current and bearing temperature and so on are obviously super-standard, etc.,

the commissioning personnel should immediately stop the heater and commissioning, findout and analyze the reasons, and then submit the solutions.

9.6 Do carefully check the oil level of bearing to be normal before starting the rubber ball

cleaning pump.

9.7 Notice to monitor the temperature variation of tile to avoid the accident of tile burning.

9.8 The personnel must wear safety helmet on the commissioning site, the leaders must inspect

the following possibly dangerous works on the job site, and eliminate the hidden dangers,

such as dropping, electric shock, scald, be injured by rotating machine, etc.


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9.9 If the safety of person or equipment is endangered during commissioning, the

commissioning works should be stopped immediately and set the equipment at the lowest

energy consumption state.


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10. Appendix

Appendix 1. Checklist for requirements of commissioning

No. Examination content Requirement Examinationdate Examination

results Remarks

1. Installation of rubber ball pump

Have been completelyfinished and recorded alltechnical data

2. Rubber ball cleaning pipe system

Have been completelyfinished

3. Electric test of motor

The test is qualified. Thesituation is good after 2-houroperation without load, andthe rotation direction iscorrect.

4. Program control ofrubber ball cleaning

Finish the test and isqualified to put into use.

5. Electric valve andadjusting valve of eachsub-system

The switch of distantoperation is flexible and thedirection is correct.

6. Ball collecting screen

and switch valve

The switch of operation isflexible and the direction iscorrect.

7. Ball loading chamber Cleaned up

8. Electric and thermalmeters

The installation is complete,and can be used afterverification

9. Road on the trial runsite

Open road, sufficientillumination and reliableemergency illumination

10. Communicationequipment on the trialrun site

Convenient and available

11. Fire-fightingequipments Sufficient

12. Maintenance personnel(including electric andthermal personnel)

Sufficient and have beentrained

13. Maintenance tools andmaterials Sufficient

14. Operation tools andrecord form Have been prepared well

15. Measurementinstruments and meters Have been prepared well

Vibrometer TachmeterListeningrod


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Remarks

Signature of commissioning leader:Date:


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Appendix 3. Commissioning record of electric valveOperation on MCC

panelOperation by

computerTime

KKSCode

NameCorrect

on-the-spotindication

Correct

direction

Correct

feedback

Correct

direction

Correct

feedback Open Close

Date Remarks

Outletelectricvalve ofrubber

ball pump AOutletelectricvalve ofrubber

ball pump B Outletelectricvalve of

ballloadingchamberA

Outletelectricvalve of

ballloadingchamberB Ballcollectingscreen A

Ballcollectingscreen B


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Appendix 4. Record of trial run parameters for the rubber ball cleaning system

DataNo. Item Unit

1 Current of rubber ball pump A2 Outlet pressure of rubber ball pump MPa3 Pressure of circulation water MPa4 Bearing temperature of motor of rubber ball

pump

5 Bearing vibration of rubber ball pump m6 Bearing vibration of motor of rubber ball pump m