Boiler

PAF

and

System

Commissioning Procedure

Compiled by:

Reviewed by:

Approved by:

2014

Qingdao Huachen Weiye Electric Power Technology

Engineering Co., Ltd.


Catalogue
1. OVERVIEW ...................................................................................3
2. MAIN EQUIPMENT TECHNIQUE
SPECIFICATION.......................................................................................3
3. COMMISSIONING BASIS AND STANDARD .....7
4. COMMISSIONING PURPOSE ...........................................8
5. COMMISSIONING CONDITION..................8
6. COMMISSIONING PROCESS AND
METHOD.....................................................................................................8
7. COMMISSIONING INSTRUMENT AND
EQUIPMENT............................................................................................11
8. COMMISSIONING QUALITY AND
ASSESSMENT STANDARD....................................................................11
9. ENVIRONMENT,
OCCUPATIONAL HEALTH AND SAFETY CONTROL
PROCEDURE............................................................................................12
10 ORGANIZATION AND DIVISION..............................12
11. APPENDIX..................................................................................15
2


Boiler PAF and System Commissioning Procedure
1.

Overview
ZMTP 2150MW
2510t/h

The project is Zambia ZMTP 2150MW coal fired power plant, located at
Maamba coal mine, Sinazongwe, Southern Province. The boiler is produced by
Dongfang Boiler Company, which is 2*510t/h high temperature, super high pressure
circulating CFB boiler. Here the procedure is for the boiler PAF and system
commissioning.

Each boiler is matched with two sets of centrifugal IDF, controlled by damper
and hydraulic coupling; two sets of centrifugal PAF, controlled by damper and
hydraulic coupling; two sets of centrifugal FDF; controlled by damper and hydraulic
coupling; three sets of HP fluidized blower, controlled by motor butterfly damper and
hydraulic coupling, which are all produced by Shanghai Blower Works Company.

2.

Main equipment technique specification

2.1
Boiler specification
Zambia MCL 2150MW Coal Fired Power Plant 2 510t/h

150MW

Zambia MCL 2150MW Coal Fired Power Plant is provided with two sets of
510t/h super high pressure, natural circulating CFB steam drum boilers, which is
single furnace, single medium reheating, thermal isolation cyclone separator, tubetype air preheater, balanced draft, end part double flue, suspension structure, halfunsheltered layout, solid state deslagging, complete steel structure, matched with
150MW condense turbine-generator. The boiler adopts CFB combustion and
limestone desulfurization technique that low pollution and high efficiency.

Boiler main parameter sheet

Item

Main steam flow

Main steam pressure

Main steam temp.

Unit
T/H

BMCR

BECR

510

485.73

MPa

14.32

14.32

540

540


LP RH inlet pressure

LP RH inlet temp.

HP RH inlet pressure

HP RH inlet temp.

RH flow

Feed water temp.

Feed
water
temp.
exclusive all HP
#1
Feed
water
temp.
exclusive #1 HP
#2
Feed
water
temp.
exclusive #2 HP
(LHV)
Boiler
guaranteed
efficiency (LHV)

Boiler
desulfurization
efficiency

MPa

2.85

2.85

334

334

MPa

2.7

2.7

540

540

T/H

420.42

400.4

248

248

171

228.6

207.3

90

92.3

2.2
Fan technique parameter

FDF system mainly comprises following equipment: two SAFs, two SAF
motors, two hydraulic couplings, two sets of auxiliary equipment of hydraulic
coupling, control and protection.
5


PAF mode and type

Mode: centrifugal
2378AB/1160
Type: 2378AB/1160

Blade mode: single suction and dual supporting

135,90()
Rotation direction: inlet 135, outlet 90 (from motor terminal)
24
Layout mode: symmetry laying, two sets for each boiler, and total four sets for
the project.
886SVTL
Hydraulic coupling type: 886SVTL

STMKK500-4L-TH
The fan is mainly composed of shell, admission box, air inlet, transmission
mechanism, blade wheel, bearing, control mechanism, etc. The fan is linked by
junction box and hydraulic coupling, driven by motor, which the type is STMKK5004L-TH,
1
Sheet 1: PAF design parameter:

Performance

SAF flow

point

Inlet negative Full

Inlet
temp.

pressure

load

pressure rising

TB

Nm3/h

Pa

Pa

215850

40

-350

26830

179875

20

-350

18632

T, B point

BMCR
Design (BMCR)
2
Sheet 2: PAF regulation

No.

Item
1

2378AB/1160

Mode

Quantity for each boiler

%

85.5

Selected point efficiency (full pressure) %

%

85.5

Guaranteed point efficiency (full pressure)

kg/h

243484

TB
Selec

8
ted

Quality flow (kg/h)

m3/h

232776

Capacity flow (m3/h)

kPa

26906

Total head pressure (kPa)

40

Inlet medium temp. ()

working

kW

condition

Shaft power (kW)

TB

10

kg/h

202824

Quality flow (kg/h)

m3/h

181584

Capacity flow (m3/h)

kPa

18332

Total head pressure (kPa)

20

working

Inlet medium temp. ()

kW

1011.2

condition

Shaft power (kW)

11

12

BMCR
Calculat

13

ed
14

1849.6

(BMCR
)
15

Q235A

16

Shell material
mm

10

17

Shell thickness (mm)

45#

18

Shaft material
/

15MnV

19

Blade wheel material

/

10

20

Blade wheel service life ( 10,000 hour)

t

3.5

21

Rotor weight (t)

t

18

22

Total weight (t)

Bearing mode

Rolling
bearing
8

23

Bearing lubricating mode

Open

24

m /h

cooling
9000

25

Allowed minimum stable flow (m3/h)

Pa

200

26

Inlet noise eliminator resistance (Pa)

Manufacturer

Xiangtan

27

water

Motor
YKK630-4

Type
kW

2050

29

Rated power (kW)

V

6600

30

Voltage (V)
r/min

1480

31

Rotation speed (r/min)

IP55

32

Protection grade

33

Cooling code

Air-air cooling

34

Bearing mode

Sliding bearing

Neutral

Dalian

28

Driven motor

point

transformer
35

current

Zhongguang
+

Flow control mode

Inlet

damper

hydraulic coupling
3
9

Sheet 3: hydraulic coupling performance parameter

Name

Unit

Rated load

Max.

Design
value

KW

Output power

Slip

KW

Slip loss

KW

Fixed loss

KW

Input power

r/min

Input speed

r/min

Output speed

Rotation direction

Driving shaft

Driven shaft

Speed

control

range

Working oil pump

mode

Lube

oil

pump
10

Name

Unit

Rated load

Max.

Design
value

mode

Startup oil pump

mode

Working

MPa.g
oil

pressure

l/min

Working oil flow

MPa.g

Lube oil pressure

l/min

Lube oil flow

Oil cooler

Design

pressure

MPa.g

of

working oil cooler

MPa.g

Design pressure of lube

oil cooler

OC

Design temperature of
working oil cooler

OC

Design temperature of
lube oil cooler

m2

11

Name

Unit

Rated load

Max.

Design
value

Cooling

area

of

working oil

m2

Cooling area of lube oil

Cooling water

t/h

Water flow of working

oil cooler

MPa.g

Cooling water pressure

drop of working oil
cooler

t/h

Water flow of lube oil

cooler

MPa.g

Cooling water pressure

drop of lube oil cooler

Introduction:
1.TB(test block)
TB (test block): allowance shall be reserved for air flow and pressure in TB
working condition.
2.BMCR BMCR
BMCR: boiler maximum continuous rating. The fan parameter shall be
checked under BMCR working condition.
3.
Above air flow and pressure data has been modified to selected state.
4.
12

The PAF is controlled by hydraulic coupling.

3.
3.1 DL/T5437-2009
Code for Fossil Power Construction Project from the Unit Commissioning to
Completed Acceptance by National Energy Administration DL/T5437-2009
3.2 DLT852-2004
Guide for Boiler Start-Up Commissioning Test by NDRC DLT852-2004
3.3 DL5009.1-2002
Code of Safety Operation in Power Engineering Construction Part 1:
Steam Power Plants by Electric Power Industry Standard
3.4 DLT
5210.2-2009
Code for Construction Quality Acceptance and Evaluation of Electric Power
Construct. Part 2: Boiler Unit by National Energy Administration DLT 5210.2-2009
3.5 1996
Standard for Quality Inspection and Evaluation on the Commissioning of
Thermal Power Plant (1996 version)
3.6 1996
Regulations on the Start-up commissioning of Thermal Power Plant Projects
(1996 version)
3.7 [2002]49
Power Construction Safety and Health and Environmental Management
Regulations, State Grid Corporation [2002]49
3.8
Relevant contracts, design drawings, manufacture introduction, technique
agreement and other documents.
3.9 MCL 2150MW
3.10

Commissioning outline of Zambia MCL 2150MW coal fired power plant

project.
13

4.

Commissioning purpose
4.1

In order to guide and regulate system and equipment commissioning, and put into
operation safely and normally, hereby the procedure is compiled.
4.2
Check electric and I&C protections interlock and signal devices, and confirm the
action reliability.
4.3
Check equipment operation and systems performance, find and remove the possible
problems.

5.

Commissioning condition
1

Before commissioning, the commissioning staff shall check the provided

condition completely for the system as per appendix 1 content and make recording.

6.

14

Commissioning process and method

PAF system commissioning work can be carried out as per following flow chart:

Technique handover

Main equipment, I&C, electrical

and air channel and valve erection
and single commissioning are

Condition confirm

completed.
Safety condition are satisfied.

15

Interlock protection test

Interlock protection

Alarm test

alarm test

PAF test running

System blowing and

tightness check

System into operation

and dynamic control

Chart 1: Commissioning flow chart

6.1
Actuator check
6.1.1
Check and accept motor air valve dampers, record data;
6.1.2
Check and accept motor control air valves, record data.
16

6.2
Thermal signal check
6.2.1

Check and accept analog and switching value signal, record data.
6.2.2

For above signal, on site position shall be considered to analyze the reality of
collected signal, if not, response and suggest to construction unit.
6.2.3
Air fan emergency button test.

The air fan emergency button erection and wire connection shall be complete
and correct, and the emergency button simulation test can make air fan trip.C

6.3
Interlock protection and alarm signal check
6.3.1

Turn the PAF power switch at test position.

6.3.2

Check following items:

DCS DCS
Start PAF on DCS with correct response;
DCS DCS
Shutdown PAF on DCS with correct response;

6.3.3

FDF protection test shall be completed as per content of interlock protection

sheet, which shall work normally.
17

6.3.4
6.3.4.1
a)
Covers for ditch and channel shall be complete; stairs, path way and guard rail
shall be complete; all sundries shall be cleaned up.
b)
Communication system commissioning shall be completed and qualified.
c)
Industrial and emergency illumination shall be complete and sufficient.
d)
Confirm that PAF and its system erection are completed.
e)
Air channel of PAF shall be cleaned up without any foreign materials that may
cause air fan damage.
f)

Manholes of PAF outlet air channel and body shall be closed and accepted.

g)
Air valves and dampers shall be checked and qualified.
h)
I&C erection and verification shall be qualified.
i)

Interlock protection driving test related to PAF shall be qualified, and

protection and alarm setting shall be completed.
j)

Electrical test and electrical interlock test shall be completed.

k)
18

PAF emergency button driving test shall be completed and qualified.

l)

PAF and its system commissioning is completed and qualified, which can be
put into operation.

m)
Manual turning PAF and its rotor shall be normal.
n)
FDF and its motor single commissioning are completed, junction box of motor
and SAF is reset completely.
o)
FDF and its motor bearings are provided with lube oil sufficiently.
p)
Insulation resistance of the motor shall be measured and qualified.
6.3.4.2
Protection or interlock that does not affect safety shall be cut off and recorded.
6.3.4.3
PAF startup preparation
a)
Carry out check as per auxiliary code before startup, which shall be qualified.
b) CRT
Confirm that PAF inlet and outlet dampers shall work well, and local opening shall
be identical with CRT display.
c)
Confirm that PAF bearing is filled with qualified lube oil.
d)
Put cooling water system into operation to observe water flow, which shall be
normal.
e)
PAF has been started.
19

f)

PAF motor insulation is qualified, then transmitting power.

g)
PAF motor insulation is qualified.
h) DCS
Confirm that DCS permissive startup PAF condition is satisfied.
6.3.4.4
Switch on FDF power and check
a)
Whether PAF rotation direction meet design requirement or not;
b)
Whether exist abnormal sound or not;
c)
Whether the system exists obvious leakage or other abnormal situation.
6.3.4.5 30

DCS
If no abnormal situation, restart PAF after 30 minutes, then gradually control
parameter of PAF control damper and hydraulic coupling, supervise PAF current to
prevent overcurrent operation. Record all operation parameter (local and DCS data
shall be recorded separately).
6.3.4.6
Operation parameter shall be supervised during operation, which shall be in normal
range.
6.3.4.7
Check the system leakage and air channel vibration.
6.3.4.8 8

20

PAF and its system commissioning shall be kept for 8 hours, then shutdown the PAF
and record the idle hour.
6.3.4.9
After PAF shutdown, cut off PAF power.
6.3.4.10
The air channel shall be freely flowing to prevent vibration caused by air valve
misoperation closing.

6.3.4
a)
72

The system reliability shall be checked as per no load stage, on-load stage, full
load stage and 168 hours operation.
b)
The system dynamic control, including primary air flow and pressure control.
c)
The equipment supervision shall be enforced during system operation,
especially during furnace negative pressure control to ensure that the system in
optimal operation condition.
d)
Fill in commissioning record.

7.

Commissioning instrument and equipment

Vibration gauge
21


Revolution meter

Infrared radiation thermometer

Clip-on ammeter

Phonometer

8.

Commissioning quality and assessment standard

8.1 1996
100% 90%

Quality standard requirements of the system and equipment shall be satisfied

according to Standard for Quality Inspection and Evaluation on the Commissioning of
Thermal Power Plant (1996 version), with 100% qualified rate and 90% excellent
rate, meeting the unit startup requirements.
8.2

The air fan operation shall be stable and normal; bearing bush temperature and
vibration, cooling water system and motor coil temperature are normal.
8.3

Professional commissioning staff and supervisor shall strictly check and control the

22

important process of commissioning quality, and report to higher level leader when
find out any problems to solve it under coordination to guarantee operation
successfully.

9.

Environment, occupational health and safety control procedure

9.1

When PAF and its system first startup, relevant staff shall be on equipment site
to supervise strictly with reliable communication to control room.
9.2 ,

When PAF test running, startup time and current shall be supervised strictly,
instantly shutdown if startup current is too long or current fluctuates rapidly.
9.3

If equipment damage or personal casualty maybe happened or has been existed,

instantly stop commissioning and analyze the cause to propose resolution
measures.
9.4
When PAF starting, rotation direction shall be monitored, if the direction is
reverse, instantly shutdown.
9.5

On-site safety regulation shall be carried out strictly by all commissioning staff to
23

guarantee the reliability.

9.6
If abnormal situation happens during the commissioning, instantly adjust it and
report it to headquarter.
9.7
Pay attention on supervising change of bearing vibration and temperature to
prevent heavy accident.
9.8

9.9 Safety helmet shall be worn during on-site commissioning, and possible danger
work shall be analyzed by person in charge on site and eliminate hidden danger.
All commissioning staff shall strictly carry out on-site safety regulation to
guarantee safety and reliability.

10

Organization and division

10.1
Erection unit
10.1.1
In charge of organization of subsystem commissioning.
10.1.2
In charge of the system isolation and closing.
10.1.3
In charge of maintenance, overhaul and troubleshooting of commissioning equipment.
24

10.1.4
Prepare necessary overhaul tools and material.
10.1.5
Coordinate with the commissioning unit to carry out subsystem commissioning.
10.1.6
In charge of temporary mark on relevant system and equipment.
10.1.7
In charge of check and acceptance after subsystem commissioning.

10.2
Construction unit
10.2.1
In charge of equipment startup, shutdown, operation control and accident elimination
during the commissioning.
10.2.2
In charge of formal mark for relevant systems and equipment.
10.2.3
Prepare operation regulation, tools and record sheet.
10.2.4
In charge of inspection and normal maintenance for commissioning equipment.

10.3
Commissioning unit
10.3.1
In charge of compiling commissioning procedure and technique handover.
10.3.2
Prepare relevant measuring instrument, apparatus and tools.
10.3.3
Engage in subsystem commissioning.
25

10.3.4
In charge of test data recording and filing.
10.3.5
Fill in inspection and qualification sheet of commissioning quality.
10.3.6
Engage in check and acceptance after subsystem commissioning.
10.3.7
In charge of compiling commissioning report.

10.4
10.4.1

In charge of supervisory work during starting and commissioning as per the contract,
supervise the procedure execution, engage in the commissioning, check and
acceptance.
10.5

PAF subsystem commissioning and single commissioning shall be charged by

erection unit, and coordinated by commissioning unit and other relevant units. The
PAF and its system commissioning shall be carried out by professionals, coordinated
by boiler, electrical and I&C, commanded under headquarter.

26

11.

Appendix
1
Appendix 1: Checking list for PAF commissioning condition

No.

Checking content

Requirement

Date

Result

Rem
ark

1-1

Complete with recording

PAF and its system erection

27

No.

Checking content

Requirement

Date

Result

Rem
ark

1-2

Complete

PAF

and

air

channel

cleaning
1-3

Complete

PAF

and

air

channel

cleaning
1-4

Lube oil quantity of all

Normal

bearings
1-5

Cooling water system

Qualified water pressure,

in operation.

2-1

Motor electrical test

Test is qualified with

correct direction after 2
hour no load running.

2-2

2-3

PAF and its system air

Flexible

valves

correct direction.

Measuring meter

Correct indication, after

operation,

verification.
28

No.

Checking content

Requirement

Date

Result

Rem
ark

2-4

Test is qualified.

Electrical

and

protection,

interlock

I&C
and

signal device
2-5

Inlet control damper

Qualified

control

and

correct direction.
2-6

3-1

Power

Reliable

On-site road

The road is unblocked

with

sufficient

illumination

and

emergency illumination.
4-1

On-site

Convenient and available

communication

equipment
4-2

4-3

Firefighting facilities

Sufficient

Enough and trained

Maintenance
(including

staff
electrical

and

thermal staff)
29

No.

Checking content

Requirement

Date

Result

Rem
ark

4-4

Maintenance

tools

and

Enough

material
4-5

Operation

tools

and

Readied

recording sheet
4-6

Test

instrument

and

Readied

apparatus

Responsible person of commissioning unit:

Responsible person of supervisory unit:

Responsible person of production unit:

Responsible person of erection unit:

Responsible person of construction unit:

Date:

30

 2
Appendix 2: Commissioning record PAF system air valves
KKS

KKS No.

Name

Remote operation

Time

Local

S R

indication

i e

correct

Cl

Correct

Correct

pe

os

direction

response

C C g m
h h n a
e e a r
c c t k
k k u
i i r

XXXXXXX

A PAF outlet
damper

XXXXXXX

B PAF outlet
damper

XXXXXXX

A PAF inlet
damper

XXXXXXX

B PAF inlet
damper

31

XXXXXXX
X
XXXXXXX
X
XXXXXXX
X
XXXXXXX
X

3
Appendix 3: PAF system interlock protection test card

No.

Test content

PAF

Startup permitted condition

1

Any side IDF is in operation condition;

30%
FDF is in operation condition, with air flow over 30%.

<5%
PAF frequency converter <5%

32

Result

Remark

No.

Test content
4

<5%
PAF inlet damper <5%

PAF outlet damper completely open

PAF no stop and protection action signal

Interlock shutdown

MFT
MFT action

All IDF shutdown

All FDF shutdown

75

Any bearing temperature of PAF front and rear bearings

is above 75 , (PAF protection interlock into operation)

80

Any bearing temperature of PAF motor front and rear

bearings is above 80 , (PAF protection interlock into
operation)

XY4.6mm/s
2S
If any PAF front and rear bearing vibration is over
4.6mm/s to X or Y direction, 2s time delay, (PAF protection
interlock into operation)

82TE-01174B~82TE01179B(62140)
145
PAF

motor

stator

coil

temperature

(82TE-

01174B~82TE-01179B) is above 145 (2 selected from 6)

(alarm when above 140), (PAF protection interlock into
operation)
Introduction

33

Result

Remark

No.

Test content

Set up on/off switch for PAF protection interlock

PAF protection action first out

II

PAF motor connection air valve

1

Input interlock: all air fans operation

Shutdown interlock: air fan single side operation

III

PAF inlet air vavle

Shutdown interlock: PAF trip

34

Result

Remark