Commissioning Measures Form for Approval

No.YDTD-TS07

Project name

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India

Contract No.

ITD-032

To: Tengda Project Department of Sichuan Machinery & Equipment Import & Export Corporation Now it is submitted for the examination and approval with the deoxygenation system commissioning technical measure Document No. :YDTD-QJCS-07

Appendix: deoxygenator commissioning technical measure

Contractor: Sichuan Tongneng Power Technology Co. Ltd.

Project principal Examination and approval opinions of the project supervision department:

Date

Project supervision department (seal)

Supervision engineer:

Date

Chief supervision engineer:

Date

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

Examination and approval opinions of the owner

Legal person of the project (seal):

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

Date

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India

Deoxygenation system commissioning technical measure

Sichuan Power Industry Commissioning Test Institute Sichuan Tongneng Power Technology Co., Ltd
Mar. 2008

Examination and Approval Record for Documents

Document name Document No. The 1st version Date of publication Date of The 2nd version Edition no. Date of publication The 3rd version Main revised content publication Main revised content YDTD-QJCS-07 deoxygenation system commissioning technical measure

Managers approval of the commission ing project Date:

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

Review of the principal of professiona l group of commission ing project Compiler of the technical Date document Date:

content

1. Compilation purpose ........................... 2. Compilation reference ......................... 3. Commissioning quality standard and object 4. Responsibility division ....................... 5. System brief introduction ..................... 6. Conditions prior to commissioning ............. 7. Commissioning work procedure .................. 8. Commissioning step ............................
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

9. Safety measure ................................ 10. Appendix ......................................

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

1. 1.1 1.2 1.3

(Compilation Purpose) Its established to instruct and regulate the commissioning of the system and equipment, and to assure it runs Its to inspect electric and thermal technical protection interlock of the deaerator system and the signal fixture, to Its to inspect the setting up status of the system & equipment, and system performance, and discover and solve

normally and safely.) make sure the proper actions. the defections which maybe existed.) 2. 2.1 2.2 2.3 (Compilation References) Project for the Basic Construction of Thermal Power Plant from Start to Finish to Check before Acceptance Regulation (1996 version) Electric Power Construction (1996) No. 159 Technical Specification for Power Construction and Acceptance (Steam Turbine Unit Chapter) DL5011-1992 Technical Regulation for Power Construction and Acceptance (Pipeline Chapter) DL5031-1994 Inspection (1996) No. 111 2.5 2.6 2.7 2.8 3. 3.1 "Regulation for the Adjustment & Trial Runs Starting of Thermal Power Project Construction Quality Inspection (1996) No. 40 Factory Drawing, Instructions for Installation and Usage, Quality Guaranty Book and Certificate of Merchandise Design Document, Drawing, Instructions, Commissioning and relevant document and meeting minutes, etc. The Supply Contract for Equipment and the international or domestic standards regulated in the contract Commissioning quality standard and object Deaerator system commissioning, it should be according to the relevant quality standards for the deaerator System and equipment and the quality requirements of commissioning contract to meet the setting up requirements for the whole units. 3.2 Professional commissioning members and professional group leaders should be check and control the key processes of commissioning in according to the Appendix 1(Quality control point to commissioning) 4. Responsibility division According to the relevant regulation of Ministerial New Starting Regulation and commissioning contract, the responsibilities for every division are as following: 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 (Installation unit) To be responsible for commissioning and trial running for every unit of the equipment; To be responsible for the isolation of the system; To be responsible for the inspection, maintenance and problem solving of the trial running equipment; To prepare the necessary maintenance tools and material; To cooperate with unit who is responsible for commissioning of the sub-system;
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2.4 Thermal Power Project Tuning & Commissioning Quality Testing & Evaluation Standards Construction Quality

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

4.1.6 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.4

To be responsible for the approval after trial running of sub-section of the system. (manufacture unit) To be in charge of setting up & stopping process, running adjustment and problems solving when the system is trial running. To be in charge of listing the official brands of the relevant system and equipment; To prepare the regulation, tool and logsheet for records for operation; To be in charge of in-process inspection (patrol inspection) and normal maintenance when trial running. Responsibility of commissioning unit: To be responsible for the preparation of the plan for the trial running, and disclose all-round technically To prepare the relevant testing instrument, meter and tools; To be responsible for directing the commissioning of the sub-system; To be responsible for making notes of the testing data and filing work; To fill in the quality evaluation sheet of the trial running; To be responsible for the approval of the trial running of the sub-system; To prepare the commissioning report; The commissioning of the deaerator unit is responsible for installation unit, but operated by commissioning unit. The commissioning of the sub-system of the deaerator is responsible for commissioning unit, and to finish the commissioning with the cooperation of the installation unit and other related units. The commissioning of the deaerator system should be conducted at the direction of the trial running group of the sub-section, and operated by professional commissioning group, pneumatic equipment group as the leader, and electric, thermal control and other relevant groups as assistant.

5. 5.1

(System brief introduction) #1 set of phase I of 2330MW project of Tengda coal-fired power plant in India takes the horizontal deaerator, its main function is to remove the oxygen, CO2 and other non-condensed gas in the condensed water; and secondly, it could heat the condensed water to the saturation temperature under the deaerator operation pressure, and stock all the saturation water with standard oxygen level to the water tank of the deaerator to supply the needs of the boiler at any time. Extraction steam by the section five of steam turbine will be the operation source when its normally worked.

5.2

Technical Specification for Equipment Inbuilt and no head Deaerator Design pressure: 1.32MPa Design temperature: 370 Boiler steam rate: 1069t/h Opening pressure of safety valve: 1.17Mpa Operation mode: steady-sliding-steady Rated temperature of heating steam: 351.14 Rated temperature of condensed water: 149.8 The highest pressure for operation: 1.0749MPaa The highest temperature for operation: 358.09 Dischargeable capability of water tank: 150 m3 Total volume: 220 m3 Variation range of pressure governing: 0.3181.0749MPa(a) The highest temperature of heating steam: 358.09 The highest temperature of condensed water: 151.86

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

Temperature of the water output: 178.44180.81 The oxygen content of water output: 7g/L PH value: 8.89.3

6. 6.1 6.2 6.3 6.4 6.5

(Conditions prior to commissioning) The deaerator system have been installed, with sufficiency illumination at the scene, roads are open; Its already finished for the washing of the condensed water system, and its clear for the water tank of the deaerator; Its washed clearly and properly for the downtake of the deaerator; Its ok for the hydraulic pressure of the deaerator system; Its blown clearly for the steam pipes of the deaerator system, and system restored;

6.6 The safety valve of the deaerator has met its operating pressure in pre-pressure when installation; 6.7 Nilometer in place should be clear and transparent, and with protection covering (if the nilometer is the magnetic type liquid level meter, the operation should be flexible and properly); 6.8 Its in the normal position for the water level of the water tank of the deaerator; 6.9 All the manual controlled valve, automatic electric valve, and adjustment valves in the system could be opened and closed properly and accurately; 6.10 All are ok for every interlock protection testing for the deaerator; 6.11 All kinds of thermal meters, transducers are ok for inspection and verification, and all could be put in place or DCS 7. (Commissioning work procedure)

The procedure for commissioning of the deaerator system as below:

1, Verification of the technical plan for commissioning and technical disclosure 2, Verification of the necessary condition before commissioning 3, Interlock protection and warning testing 4, safety valve of the deaerator adjustment; 5, trial running of the system and adjustment; 6, document filing with signature
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

8. 8.1

(Commissioning step) executing organization inspection to inspect the automatic electric valve and record the following data: a) b) c) d) e) f) KKS code; name (if there is any detailed description from the power plant, and then take it as standards); the position in place instructs correct or not? the operating direction on the electric control plate is correct or not, and the feedback is correct or not? the operating direction on the CRT is correct or not, and the feedback is correct or not? the opening and closing time for the valve. KKS code name (if there is any detailed description from the power plant, and then take it as standards); the position in place instructs correct or not? the operating direction on the CRT is correct or not, and the feedback is correct or not? is there any quick-opening and quick-closing function? KKS code; Name (if there is any detailed description from the power plant, and then take it as standards); Whats the instructions for the corresponding position in place and the feedback as when the upper line is 0%25%50%75%100% and when the lower line is 100%75%50%25%0%? d) is there any quick-opening and quick-closing function?

8.1.1

8.1.2

to inspect the steamed switch valve, and record the following data: a) b) c) d) e)

8.1.3

to inspect the steamed adjusting valve, and record the following data: a) b) c)

8.1.4

To analyze the effect will probably be occurred under the condition of power off or gas off by the above executing organization, and if there is larger impact, its need to show the contact list and explain the danger to the owner.

8.2 8.2.1

Thermal technical signal inspection to inspect the analog signal, and record the data below: a) b) c) signal name KKS code range, and corresponding output and units signal name KKS code designed value of the signal to install the value showed in the verified certificate of the primary component

8.2.2

to inspect the switch quantity signal, and record the below data: a) b) c) d)

8.2.3 8.3 8.3.1

For the above signal, the PIC (person-in-charge) should analyze if all the signal collected could truly represent all which need to be measured according to the position the signal collected. Interlock protection and alarming/warning inspection Water level of the deaerator protection
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

a) b)

If the water level value of the deaerator is higher than 1 stage (2650mm), it will warn, and turnoff the bypass control valve and main inlet control valve; If the water level of the deaerator is higher than 2 stages (2850mm), it will alarm, and turn on the deaerator overflow valve, and turnoff No. 6 high pressure heater to drain valve of deaerator, the section five extraction steam to the electrical isolation valve of deaerator, auxiliary steam to pressure adjusting valve of the deaerator, and set up the min flow of recycle valve.

c)

If the water level of the deaerator is higher than 3 stages (2950mm), it will alarm, and turn on from the deaerator to condenser overflow valve and condensing pump recycle, and turn off from the section three extraction steam to automatic electric valve and check valve, and turn on section 3 extraction steam pipeline drain valve.

d) e) 8.3.2

If the water level of the deaerator is lower than 1 stage (2250mm), it will alarm. If the water level of the deaerator is lower than 2 stages (1400mm), it will alarm, and will link to the pump to protect it to trip.

Deaerator pressure interlock protection a) b) When the deaerator pressure is lower to 0.2MPa, it will turn on from auxiliary steam pressure to deaerator electric valve, and the drain valve turn on automatically; When section five extraction steam pressure increased to 0.2MPa, it will automatically set up from section five extraction steam to deaerator steam valve, and the drain valve will turn off automatically, and it will turn off automatically from the auxiliary steam pressure to deaerator pressure adjusting valve;

8.4 8.4.1 8.4.1.1 8.4.1.2 8.4.1.3 8.4.2 8.4.2.1 8.4.2.2 8.4.2.3 8.4.2.4 8.4.2.5 8.4.3 8.4.3.1

Trial Running of the Deaerator Preparation and inspection before trial running of the deaerator To check if all the system related with the deaerator, including the deaerator, are all in the normal situation, and also the pressure gauge, thermometer, and nilometer; To confirm if all automatic electric valve and adjusting valve could operate well, and all shows normal for the relevant interlock protection testing. Installation corp. should make a initial water pressure/steam pressure adjustment to the deaerator safety valve. The deaerator should be washed before the trial running. The deaerator washing could be proceeded when its ok for the condenser and condensed water system cleaning and washing. Set up the condensed water pump when the water lever of the condenser is normal. Manual control the water-in adjusting valve of the deaerator, and let the water into the deaerator; Open the water-out valve slowly, and wash it Keep the condenser water level and condensed water pump run normal, and turnoff the water-out valve to stop washing until the water quality meet the requirements of the water which will be in the deaerator. Keep the water in to the condenser till the water level is in the normal situation. Deaerator input To confirm if its normal for the water level
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

8.4.3.2 8.4.3.3

To check if the deoxygenated door of the deaerator with proper opening Operate the auxiliary steam to the deaerator pressure adjusting valve by hands, and rise the pressure to 0.2MPaand maintain the operation with rated pressure.

8.4.3.4 8.4.3.5

Turn on the water-in valve of the water supply pump to warm the pump. After network incorporated generating unit, and when the extraction pressure of section 5 arrived 0.2MPa, it will turn on from the extraction steam of section 5 to steam supply electric valve of the deaerator, and drain valve and auxiliary steam to deaerator pressure adjusting valve will be turned off automatically, and it will be sliding pressure running.

8.5 8.5.1

normal running and maintenance of the deaerator regulation of the parameters for the normal running Deaerator pressure 0.20.95 MPaa saturation temperature to corresponding pressure 2450mm(middle line of the water tank of the deaerator) 7ug/L

Deaerator temperature Deaerator water level 8.5.2 8.5.3 8.5.4 8.5.5 8.6 8.6.1 8.6.2 8.6.3

Oxygen amount of the deaerator

Often check if there is no any water leakage and vibration of the deaerator system, and inspect if the indications of the meters in place and far-off meters are the same. Often check the water level and the flexibility of the pressure controller and all kinds of valves operation. To make sure the oxygen amount of the deaerator is OK, and adjust the open quantities of the deoxygenized valve. To enforce the system inspection in the winter, to prevent freezing and breakage of the equipment, meters/gauge and pipelines and false indicating situations. Stop Running of the Deaerator We should keep eyes on the running status of the deaerator, as the pressure will be fallen down along with the load fall of the assembly units; Pay attention to the variation of the pressure when its stopped for the high pressure drain When the deaerator pressure decreased to 0.2MPa, it will automatically set up for the auxiliary steam, and it will automatically turn off for the section five extraction steam to deaerator steam supply valve, and the drain valve will be turned on automatically.

8.6.4

When the water supply pump cease to run, the auxiliary steam to deaerator adjusting valve should be turnoff by hands, and stop deaerator heating, and turn off auxiliary steam to automatic electric valve, and set up pipeline drain valve.

8.6.5 8.6.6 8.6.7

Change the deaerator water level control to manual control, and turn off the water-in adjusting valve, and the lower pressure condensed water out electric valve. If the deaerator will be ceased to use for a long time or under the inspection situation, the water should be drained away. If the deaerator will be ceased to use for a long time, it should be isolated for protection with nitrogen according to the chemical requirements, and the nitrogen pressure should be maintained to 0.03 MPa to prevent corroding by the harmful gas to the water tank wall of the deaerator.

8.7

System Adjustment under Operation

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

Enforce the management to all equipments when trial running, and adjust it if any abnormal running occurred, to make sure that the system is under the best running situation. a) b) c) d) 8.8 Pressure adjustment Temperature adjustment Flux adjustment Water level adjustment

Fill in the trial running record All the main data/parameter collected in the trial running should be noted down in the logsheet 8 of Trial Running Parameter Logsheet for Deaerator System.

9. 9.1 9.2

(Safety measure) All members who have take a part in the commissioning should be seriously carry out the Safety Regulation and the relevant regulations on the spot to make sure the operation be completed safety and properly; The commissioning operation should be stopped immediately, and the equipment should be adjusted to the lowest energy consumption status, and then analyze the reason and come up with the solving methods when there is any equipment likely to be or already damaged or personal injury or death occurred.

9.3 9.4 9.5 9.6

It should be adjusted in time and report to the commander timely when there is any abnormal occurred when commissioning. Every kinds of professional members should be on the spot for the whole commissioning process to make sure safely operation for the equipment. The commissioning members should analyze the reason and propose the solving actions when the running equipment or pipeline with extreme vibration. Every operator should wear the safety helmet when commissioning, and all the dangerous work leaders should analyze the spot to eliminate the hidden danger, such as crashes, electric shock, burns, mechanical rotating cutter injury, etc.

9.7 9.8 9.9 9.10 10.

The steam amount should be controlled to avoid the temperature increased too fast when heating up the steam. to prevent the deaerator pressure from quick rise or quick fall; to prevent the deaerator water level from quick-increase or quick-decrease; to prevent the vibration of the deaerator (Appendices)

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Appendix 1 Inspection List of the Necessary Condition before Commissioning No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. INSPECTION ITEMS Deaerator installation Installation for deaerator pipeline system Safety valve of deaerator Condenser and condensed water system deaerator system valve electric and thermal technical meter electric and thermal technical protection, interlock and signal device dynamical power spot for trial running Communication equipment on the trial running spot Fire protection equipment inspector (including electric and thermal technical members) Inspection tools and material running tools log sheet for records Instrument, meters REQUIREMENTS finished and all technical data be noted down Finished, hangers have been adjusted both ok for the water or steam pressure adjustment, installation finished its ok for washing Commissioning finished, operate and running properly Be verified and confirmed, indicate correctly testing ok reliable roads are open with sufficiency illumination at the scene reliable accident illumination could be used conveniently enough quantity enough quantity be trained enough quantity ready ready INSPECTI ON DATE INSPECTI ON RESULT REMARKS

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

Remarks:

PIC for commissioning:

Date: M /D/ Y

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Appendix 2 Commissioning Log sheet for Electric Switches Valve KKS Code 20LBS40AA001 20LBS40AA004 20LBG50AA001 20LAA10AA501 20LAA30AA501 20LAA20AA501 20LAA40AA401 20LAA41AA401 10LAA42AA401 Name Extraction steam of section 4 to deaerator steam supply valve 1 Extraction steam of section 4 to deaerator steam supply valve 2 Auxiliary steam to deaerator steam supply valve setting up the exhausting electric valve 1 of the deaerator setting up the exhausting electric valve 2 of the deaerator Deoxygenated electric valve of the deaerator Urgent water-out electric valve of the deaerator Deaerator outflow to condenser electric valve Deaerator to water-out electric valve correct indication in place MCC plate operation correct direction correct feedback DCS operation correct direction correct feedback time (s) turn on turn off Date Signature

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

Appendix 3 Commissioning Log Sheet for Pneumatic Switch Valve KKS Code Name correct indication in place DCS operation correct direction correct feedback Function Quick switch on Quick switch off Date signature

20LBS40AA002 20LBS40AA003 20LBS40AA401 20LBS40AA402

Extraction steam of section 4 to check valve 1 Extraction steam of section 4 to check valve 2 Extraction steam of section No. 4 to the front pipeline drain valve of deaerator steam supply valve 1 Extraction steam of section No. 4 to the front pipeline drain valve of deaerator check valve 2

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Appendix 4 Commissioning Log Sheet for Pneumatic Adjusting Valve Indications as the below value, and the feedback will % be 0% 20LBG50AA101 Auxiliary steam to deaerator pressure adjusting valve 25 % 50 % 75 % 100 % 75 % 50 % 25 % 0%

KKS Code

Name

quick switch on and off function

Date

signature

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

Appendix 5 Log sheet for Interlock Protection of Deaerator No. 1 Testing content Setting up steps for the deaerator. 1.Turn on the extraction steam of section No. 4 to the front pipeline drain valve of deaerator steam supply valve 1 2.Turn on the extraction steam of section No. 4 to the front pipeline drain valve of deaerator check valve 2 3.Turn on the check valve 1, 2 of the extraction steam of section 4 4.Turn on the extraction steam of section No. 4 to the deaerator steam supply valve 2 5.Turn on the extraction steam of section No. 4 to the deaerator steam supply valve 1 when the extraction steam pressure is over the parameter (>0.15MPa), 6.Delay 5 minutes, turn off the pipeline valve of the front of extraction steam to deaerator steam supply electric valve 1, and the back of the extraction steam of section 4 to the deaerator stem supply check valve 2 Deaerator ceasing steps 1.Turn off the Extraction steam of section 4 to deaerator steam supply valve 1 2.Turn off the check valve 1, 2 of the extraction steam of section 4 3.Turn off the extraction steam of section 4 to the front pipeline drain valve of deaerator steam supply valve 1 4.Turn off the extraction steam of section 4 to the front pipeline drain valve of deaerator steam supply valve 2 5.Turn off the extraction steam of section 4 to the deaerator steam supply valve 2 Deaerator water level protection 1.If the water level value of the deaerator is higher than a stage, it will warn, and turnoff the bypass control valve and main inlet control valve; 2.If the water level of the deaerator is higher than 2 stage, it will alarm, and turn on the deaerator overflow valve, and turnoff No. 3 high pressure heater to drain valve of deaerator, the section 4 extraction steam to the electrical isolation valve of deaerator, auxiliary steam to pressure adjusting valve of the deaerator, and set up the min flow of recycle valve. 3.If the water level of the deaerator is higher than 3 stages, it will alarm, and turn off the section 4 extraction steam to check valve 1, 2, and turn on the pipeline drain valve in the front of section 4 extraction steam and at the back of deaerator electric valve 1 4. Normal deaerator water level (not higher), discharge #3 high pressure heater to drain valve, turn off overflow
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inspection date

Result

signature

2.

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

No.

Testing content valve. 5. If the water level of the deaerator is lower than 1stage, it will alarm. 6. If the water level of the deaerator is lower than 2 stages, it will alarm, and will link to the pump to protect it to trip. Deaerator pressure Interlock protection 1. When the deaerator pressure decreased to 0.15MPa, auxiliary steam will run automatically, and extraction steam valve and check valve of section 4 will turn off automatically, and the drain valve will turn on automatically. 2. When section 4 extraction steam pressure increased to 0.15MPa, it will automatically set up from section 4 extraction steam to deaerator steam valve, and the drain valve will turn off automatically, and it will turn off automatically from the auxiliary steam pressure to deaerator pressure adjusting valve; interlock turnoff conditions of section 4 extraction steam valve 1. the turbine trip 2. generator stepout 3. OPC operation 4. with higher deaerator water level 5. deaerator pressure>1.3MPa 6. Deaerator pressure<0.15MPa, and auxiliary steam to deaerator pressure adjusting valve is turn on. check valve 1, 2 of extraction steam of section 4 1. the turbine trip 2. generator stepout 3. OPC operation 4. with highest deaerator water level 5. deaerator pressure>1.3MPa 6. deaerator pressure<0.15MPa, and auxiliary steam to deaerator pressure adjusting valve is turn on. the pipeline drain valve in the front of extraction steam valve 1 and at the back of check valve 2 1. the turbine trip 2. generator stepout 3. OPC operation
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inspection date

Result

signature

6.

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Deoxygenation system commissioning technical measure

No.

Testing content 4. with highest deaerator water level 5.The temperature difference between the top and bottom of the extraction steam pipeline of section 4 is over 50 6.Electric load <20% deaerator steam discharging valve With high deaerator pressure>1.0MPa, turned on With non-high deaerator pressure1.0MPa, turned off

inspection date

Result

signature

Recorder:

Testing Date:

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