BOILERS COMMISIONING

BY
THERMAX BABCOCK & WILCOX

WHAT IS COMMISSIONING?
MEANS
BRING LIFE INTO THE BOILER
AUXILLIARIES AND ASSOCIATED
SYSTEMS.
MAKES THE BOILER & SYSTEMS
OPERATIONAL.

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COMMISSIONING - WHY?
FIND ALL THE POSSIBLE AREAS OF
TROUBLE BEFORE OPERATION AND
RECTIFY.
TUNE THE UNIT FOR OPTIMUM
PERFORMANCE

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PROCESS

Commissioning

Customer's order, OTF, MOM of KOM, contract change

document, IBR.

CONTROLS

OBJECTIVES

COMMISSIONING
PROCESS

To ensure that the boiler performance meets the stated (and implied)
customer's expectations.

INPUTS
Advise from project
for commissioning
start(in any form).

Boiler ready for

commissioning.

PROCESS

OUTPUTS

Depute commissioning
engineer - carry out
inspection for erection
completion-prepare punch
list,if needed- finalize
commissioning schedule with
the customer at the site execute and review
comm.plan and update handing over of boiler to
customer.

Punch list for

pending items.

PG test report and H/O

document.

List of pending items.

feed back on DDP

item, if any.

MECHANISM / RESOURCES
Expertise in boiler operation
process engineering support,
calibrated instruments, customer
support and readiness.

PROCESS MEASURES
Throughput Time plan v/s actual.
Annual report of total number of boilers
commissioned v/s plan.

ISO references for this process.

Clause: 6.2 Human resources. 7.2.3 : Customer communication. 7.3.6 : Design and
development validation. 8.2.4 Monitoring and measurement of product.

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METHODS

PRE-COMMISSIONING
COMMISSIONING
LOAD TRIALS
PERFORMANCE TESTING

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COMMISSIONING DOCUMENTS

O & M MANUALS
ISO MANUALS
CHECK SHEETS / QAP
DESIGN DATA SHEETS
STAGE PROTOCOLS
FEED BACK - CAR / IOM
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PRE-COMMISSINING
OBJECTIVE
TO ENSURE THE INSTALLATION
COMPLIANCE TO CRITICAL
DIMENSIONS AND TOLERANCES AS
PER DESIGN DOCUMENTS.

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WHAT TO LOOK FOR ?

INSTALLATION AS PER DESIGN SPECS.

ALIGNMENT
SUPPORTS & SPRING HANGERS SETTING
EXPANSION CLEARANCES
PROCESS TAPPING POINTS
ACCESS FOR OPERATION & MAINTENANCE
REFRACTORY & INSULATION
OTHERS CASE TO CASE BASIS CHECK LISTS

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COMMISSIONING ACTIVITIES

SYSTEM CLEANLINESS CHECK

TRIAL OF AUXILIARIES
LEAK TEST
REFRACTORY DRY OUT
ALKALI BOIL OUT
STEAM BLOWING
SAFETY VALVE FLOATING
TUNING - PARAMETERS AND INSTRUMENTS.
PG TEST
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SYSTEM CLEANLINESS
OBJECTIVE
TO ENSURE THE SYSTEMS ARE
CLEAN WITHOUT ANY FOREIGN
MATERIALS LIKE MILL SCALE,
CONSTRUCTION MATERIALS,
SCRAPES, TEMPORARY SUPPORTS
ETC.
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TRIAL OF AUXILIARIES
OBJECTIVE
TO ENSURE THAT THE PRIME
MOVERS AND EQUIPMENTS ARE
PERFORMING AS PER
REQUIRMENTS

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LEAK TEST OF DUCT & SYSTEM

OBJECTIVE
TO ENSURE THAT THE SYSTEM IS
PROPERLY INSTALLED TO AVOID
ANY LEAKAGES OF FLUID FROM
AND TO THE SYSTEM.

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LEAK TEST OF DUCT & SYSTEM

LEAK TEST AREAS
AIR & FLUE GAS PATH
FURNACE
WATER & STEAM CIRCUIT
OIL CIRCUIT
GAS CIRCUIT
OTHERS IF SPECIFIED
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REFRACTORY DRYOUT
OBJECTIVE
TO ENSURE PROPER DRYING AND
CURING OF REFRACTORY APPLIED
IN THE CUMBUSTOR AND OTHER
COMPONENTS

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ALKALI BOILOUT
OBJECTIVE
TO ESTABILISE THE PRESSURE
PARTS INTERNAL CLEANLINESS
FREE FROM OIL & GREASE WITH
THE HELP OF CHEMICAL BOILOUT

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STEAM BLOWING.
OBJECTIVE
TO ENSURE THE CLEANLINESS OF
SUPERHEATERS AND MAIN STEAM
LINE FREE FROM RUST, DIRT, AND
MILL SCALE TO GET THE REQUIRED
QUALITY STEAM FROM BOILER FOR
PROCESS.
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SAFETY VALVE SETTING

OBJECTIVE :
TO ENSURE THAT THE SAFETY
VALVES FUNCTIONING PROPERLY
AT THE DESIGNED / SET
PRESSURES.

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COMMERCIAL STEAMING..
BOILER TUNING
OPERATION PARAMETERS SETTING
AUTO OPERATIONS
MATCH DESIGN VS ACTUAL
PARAMETERS.

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PERFORMANCE TRIALS
OBJECTIVE
TO ENSURE THE UNIT IS
OPERATING AT DESIGNED /
GUARANTEED CONDITIONS.

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THANK YOU

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