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Commissioning Procedure for Boiler Unit Startup Page: 1 of 21 Document Class E07007 1 CHENGDA ENGINEERING CORPORATION OF CHINA CHENGDA JOB NO. E07007 A For approval Nov. 20, 2008 Zhou ZT Rev. Description Date OWNER’S DWG. NO. Prepared Checked Reviewed Approved PT. PLN (PERSERO) PT. PLN (PERSERO) JASA SERTIFIKASI (LMK) DWG. NO. Client’s Project No. PLTU 2 BANTEN-LABUAN (2x300MW) Labuan, Banten, the Republic of Indonesia E07007-PR-TM-1010 Revision No. A Electronic File Name: Date of Issue: Nov. 20, 2008 This document is restricted. Neither he whole nor any part of this document may be disclosed to any third party without the prior written consent of Chengda Engineering Corporation of China, in which the copyright of this document is vested. All copyrights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior consent of the copyright owner.
Commissioning Procedure for Boiler Unit Startup
1. Purpose
There are 3 stages in boiler unit startup period that are no load, load and full load. The purpose of this procedure is to provide the commissioning procedure for boiler unit startup, ensure that boiler unit could complete trial operation and can satisfy normal running.
2. Reference document
Drawing NO：F289S-J0201B-02（03、04、16、17、18）
3. Instrument
DCS and Local meters for parameters.
4. Safety precautions
(1) If something endangering the safety of people or equipment happen in commissioning period, correlative tests must be stopped, and if necessary the unit should be stopped operating.
(2) Test must be stopped if dangerous occurred to body and equipment during trial operation, which should be stopped if necessary
(3) Intensify inspection before startup and eliminate defects of equipment during cold condition test. Boiler unit startup should comply with curves of temperature, pressure and load as specification and move as slowly as possible.
(4) Check expansion position of boiler when boiler startup and halt if expansion badness.
(5) In order to protect RH safety, gas temperature out of furnace should be controlled below 540 ℃ as there is no steam flow to RH after boiler fired.
(6) Avoid main steam and RH steam from fluctuating and water carryover when turbine startup.
(7) Pay attention to equipment automatic start and stop during boiler unit startup.
(8) Check gas temperature out of AH and avoid secondary combustion. Soot blowing must be put into service at once when temperature is abnormal. Intensify AH soot blowing every two hours early of boiler startup
(9) Intensify check of furnace pressure change and combustion condition,
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Commissioning Procedure for Boiler Unit Startup
specially ignitors and mill startup and stop. Adjust to keep combustion stabilization.
(10) Keep exhaust gas temperature and flue gas oxygen concentration in specified range and control flue gas oxygen concentration at 4%～5%.
(11) Check auto-loops of furnace negative pressure, secondary air pressure, main steam pressure, water level, main steam temperature and RH steam temperature.
(12) Check flame detector and furnace flame TV normal and adjust combustion at any moment.
(13) Check furnace flue gas temperature probe and soot-blower to identify they boost and quit at right place.
(14) Check wall temperature of SH and RH when startup and operation to prevent pipes from break down.
(15) Intensify combustion adjustment and put oil to support combustion when load is 60%MCR below or combustion unstable.
(16) Fuel oil system is standby during boiler unit operation. Oil gun must be removed from furnace when stop.
(17) Choose appropriate coal fineness. Gas temperature out of mill should be below 75℃
(18) Pay attention to steam temperature and pressure, load, surface temperature and flue gas temperature changes after coal throwing, and avoid temperature excess.
(19) At the beginning of coal throwing, slag removing should be one time each shift.
(20) Check bearing temperature, lube level, cooling water, etc. of rotary equipment.
(21) Facilities should be checked regularly and no more than twice each shift.
(22) Intensify security when trial operation.
(23) If there is something not mentioned in this scheme, perform according to operation regulation and accident disposal regulation.
5. Necessary conditions for boiler unit startup
There is turn over package from construction team to commissioning
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Commissioning Procedure for Boiler Unit Startup
team said that system ready to test. 5.1 Site condition
(1) Site is even and traffic is smooth, civil woks has been finished and there is crawl and alarm sign at dangerous place.
(2) Platform is removed and site is clean. (3) Ladder and rail are installed. (4) Fire fighting system is ok.
(5) Drainage system can be put into service and cover boards of ditches are all ready.
(6) Water supply is ready. (7) Lighting is enough.
(8) Equipment, pipe and valve are named with symbol hanged. (9) Communication system is ready. (10) Pipes are painted and accepted.
(11) Air condition and aeration facility are ready. (12) Elevator is in service.
(13) Fuel system and coal transfer system have been put into service. (14) Coal bunker, ash hopper and boiler inner are clean. 5.2 Subsystem condition 5.2.1 Defects removed
Gas and air system has been put into service during boiler steam blowing period, whose Defects have been removed. 5.2.2 Water and steam system
(1) Temporary pipes have been resumed.
(2) Hydraulic pressure pins of safety valves of main pipe and RH pipe have been removed.
(3) Defects of drainage system, blow down system and air discharge system have been removed.
(4) Expansion indicators are all ready.
5.2.3 Coal pulverizing system (no put into service during steam blowing period)
(1) Mill has been installed with motor run and static check completed. (2) Individual commissioning of Coal feeder has been completed with
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Commissioning Procedure for Boiler Unit Startup
belt balance verified. 5.2.4 Fuel oil system
(1) Defects during steam blowing period have been removed. (2) Flame detector of oil is ready. (3) Boost and quit test of oil gun. (4) Logic function check of oil gun. 5.2.5 Coal transfer system
Individual operation of coal transfer system has been completed which is satisfied with coal feed. Different coal should be parted in coal storage. 5.2.6 Ash handling system
Ash handling system can be put into service. 5.2.7 Slag handling system
Slag handling system can be put into service. 5.2.8 Soot blowing system
Static action of soot blower is normal and soot blowing logic function is eligible.
5.2.9 Chemical dosing and sampling system
Chemical dosing and sampling system, periodic blow down and continuous blow down system, drainage system, air discharge system, anti-flush system and filling nitrogen system have all been installed. 5.2.10 Auxiliary equipment logic
SCS and FSSS check have been finished.
5.2.11 Flame detector and flame TV can be put into service. 5.2.12 Gas temperature probe
Furnace gas temperature probe has been tested and adjusted with flexible and credible operation. 5.2.13 BTG test
BTG test of unit have been completed and eligible with correct action. 5.3 Other condition
(1) Chemical making up water system can supply eligible demineralized water.
(2) Compressed air system can supply eligible compressed air. (3) House supply system is eligible.
(4) Lighting and communication system is ready.
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