Boiler ESP System Commissioning

Procedure

Compiled by:

Audited by:

Approved by:

Qingdao Huachen Weiye Electric Power Technology Engineering

Co., Ltd.

2014


Catalogue
1 ..........................................................................................................................

Introduction.......................................................................................................................... 1
2 ...................................................................................................................

3 ...................................................................................................................

Commissioning Basis.........................................................................................................

4 ...................................................................................................................

Commissioning range.........................................................................................................

5 ................................................................................

Commissioning Conditions.................................................................................................. 7
6 .....................................................................................................

10

Commissioning Methods and Steps................................................................................

10

7 ...........................................................................................

24

Commissioning Quality Check standard.........................................................................

24

8 .......................................................................................

24

Commissioning Records..................................................................................................

24

9 ............................................................................................................

25

Organization and Divisions.............................................................................................. 25

10 .........................................................................

25

HSE Control Measures..................................................................................................... 25

1
Introduction

The commissioning of electronic precipitator is to check if the voltage endurance

capacity of all the HV insulation components should be as required; make sure the anode
and cathode rapping device rotary pars and bearing parts are in normal condition; the
rapping reduction gear is in normal operation; by checking the strictness and integrity of
the proper, gad ducts, manholes and so on parts to give guarantee for the electronic
precipitator in whole-set trial-run.

Zambia MCL 2150MW Coal Fired Power Plant( MCL 2150MW

) 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, tube-type air
preheater, balanced draft, end part double flue, suspension structure, half-unsheltered
layout, solid state deslagging, complete steel structure, matched with 150MW condense
turbine-generator.
6
2 1 12
6
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, tube-type air
preheater, balanced draft, end part double flue, suspension structure, half-unsheltered
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.

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.

2.1 BMCR
Boiler main technology parameters in BMCR

name

unit

value

BMCR

t/h

510

superheaters outlet
steam pressure
superheaters outlet
steam temperature
reheating steam flow

MPa

14.32

540

t/h

420.42

reheaters inlet steam

pressure
reheaters otlet steam
pressure
reheaters inlet steam
temperature
reheaters outlet
steam temperature
ECON inlet FW
temperature
TRL
boiler guaranteed heat efficiency
(LHV, TRL)

MPa

2.85

MPa

2.7

334

540

248

90

2.2
Main accessory equipments sepcifications

1.1 IDF spec.

model
Qty.

1854AZ/1745
/

2
3

IDF
IDF

model

1854AZ/1745

air flow

Nm3/h

425020

total pressure

Pa

7700

speed

RPM

980
Shanghai Blower Works Co., Ltd.

manufacturer

motor rated vol.

6600

motor rated power

kw

2100

motor
manufacturer

Xiangtan Motor Factory

1.2 PAF spec.

PAF

model

2378AB/1160

Qty.

air flow

Nm3/h

215850

total
pressure

Pa

26830

speed

RPM

1480
Shanghai Blower Works Co., Ltd.

manufacturer

motor rated vol.

6600

motor rated
power

kw

2050

motor
manufacturer

Xiangtan Motor Factory

1.3 FDF spec.

FD

model

2248B/1065

Qty.

air flow

Nm3/h

186610
4

FD
F

model

2248B/1065

total
pressure

Pa

18550

speed

RPM

1480
Shanghai Blower Works Co., Ltd.

manufacturer

motor rated vol.

6600

motor rated
power

kw

1480

motor
manufacturer

Xiangtan Motor Factory

1.4 HP fluidizing fans spec

HP
flui
dizi
ng
fans

model

C155-1.5282/0.930

Qty.

air flow

Nm3/h

7500

total
pressure

Pa

61100

speed

RPM

2980
Shanghai Blower Works Co., Ltd.

manufacturer

motor rated vol.

6600

motor rated
power

kw

220

motor
manufacturer

Xiangtan Motor Factory

2.3
Fuel conditions

1.4 coal materials

Description

Range
5

of

Coal

Coal Analysis

Proximate Analysis (ADB)

Ash
Volatile Matter (ADB)
Fixed Carbon (ADB)
Inherent Moisture (ADB)
Total Moisture
Normal Heating Value
Ultimate Analysis
(as received basis)
Carbon (C)
Hydrogen (H2 )
Nitrogen (N2)
Oxygen (O2)
Sulphur (S)
Moisture (H2O)
Ash
Gross calorific value (as received
basis)
Hard grove index
Ash Analysis
Silica (SiO2)
Alumina (A12O3 )
Iron Oxide (Fe2O3)
Titanio (TiO2)
Phosphoric Anhydride (P2O5)

Analysis

Performance

Worst

%
%

45.3 to 53.27
19.6 to 18.05

48.3
18.8

53.27
18.08

%
%
%
Kcal/kg

33.7 to 27.47
1.4 to 1.21
1.9 to 2.1
4059 to 2990

31.55
1.35
1.9
3500

27.44
1.21
2.1
3110

%
%n
%
%
%
%
%
Kcal/kg

42.8 to 37.06
2.81 to 2.33
0.93 to 0.72
6.45 to 6.08
1.0 to 2.0
1.43 to 1.24
45.3 to 53.25
4039 to 3191

37.5
2.45
0.85
6.20
1.7*
1.90
49.4
3580

33.26
2.33
0.72
6.34
1.7*
2.1
53.55
3191

59

59

61.08
30.52
4.10
3.1
0.43

61.13
30.89
3.63
3.44
0.37

HGI
%
%
%
%
%

59
61.7 to 61.13
31.0. to 30.89
4.8 to 3.63
3.00 to 3.44
0.50 to 0.37

2.4
ESP spec.

No.
1
2
3
4
5
6
7

item

unit

ESP model
ESP
inlet flue gas flow
inlet flue
gas temperature
inlet dust
content
ESP efficiency
Proper

resistance
Proper air
leakage coefficient

value or contents
2FAA6*45M-1*144-150

m3/h

g/Nm3

152.10 m3/s 3%
worst coal and S content 3%
142.38

64.21/89.5 design/
check coal
99.94

Pa

200Pa


No.
8
9
10
11
12
13
14
15

16

17
18
19

20
21
22
23
24

item

noise
Total specific
collection area
valid section
area
length and height
ratio
/

chamber/filed
homopolar
space
total
anode area and type

Total discharge electrode

length of ESP

cathode line type and

material

value or contents

unit
dB(A)

85

m2

58320

m2

216

1.8

1/6

mm

400

m2

29160/ stereotype 480C

barbed lines 24300m/

helix 9720m

flue gas
hasten speed
flue gas speed

cm/s

RSB barbed lines 1-5

fields SPCC/
helix
6
6th
field 316
4.08

m/s

0.7

designed shell positive

and negative pressure
shell
materials and spec.

Each ESP ash bucket Qty

Anode

vibrating mode
cathode
vibrating mode
ash buckets
Qty.
ash buckets
volume

kPa

+9.8 ,-11.2

Q235

m3

6mm

36

side mechanical

side mechanical

36
104.5


No.

item

material level
meters Qty.

unit
/

value or contents
72

3
Commissioning Basis
DL/T5437-2009
Code for Fossil Power Construction Project from the Unit Commissioning to
Completed Acceptance DL/T5437-2009
DL5009.12002
Code for Construction Acceptance and Evaluation of Electric Power Construct. Part 2:
Boiler Unit by National Energy Administration DLT 5210.2-2012
[1996]111
Standard for Quality Inspection and Evaluation on the Commissioning of
Thermal Power Plant (1996 version)
1996
Regulations on the Start-up Commissioning of Thermal Power Plant Projects (1996
version)
DL/T852-2004
Guide for Boiler Start-Up Commissioning Test by NDRC DLT852-2004
DL/T5047-95
Code for Construction Acceptance and Evaluation of Electric Power Construct. Part 2:
Boiler Unit DL/T5047-95
GB1018488
"Power Plant Boiler Performance Test Regulations" (GB1018488)

"Safety Work Regulations for Electric Power Industry" (Thermal and Mechanical
Part)

Manufacture and design drawings, equipments erection and manuals.

4
Commissioning range

ESP proper, cathode and anode rapping systems, electric heater, HV rectifier
transformer

5
Commissioning Conditions
5.1.

The ESP proper, equipments and systems have been installed, the process and erection
quality be as required by the manufacturer and designer. Supply the erection records and
technical materials in document pact.
5.2.
Site clean, pathway smooth, railings complete and illumination adequate.
5.3.

All the electric ceramics have gone through the voltage withstand tests before installation.
Every part is clean, the insulator chamber with no water, and field is clean with qualified
insulation.
5.4.

After commissioning, the HV and LV electric equipments are as required. The HV cables
have passed the voltage withstand tests. The electric circuits connection checked correct.
The HV control cabinets have passed the energizing tests and regulation, with correct
motion directions, and the local and remoter operations should be smooth and reliable.
5.5.
There is no stuff with flammability and explosion potential at or around the trial-run site,
and there are adequate fire-fighting devices at the site.
9

5.6.

There is no stuff with flammability and explosion potential at or around the trial-run site,
and there are adequate fire-fighting devices at the site.
5.7.

The electronic ash hopper and storage pump have installed, the intake flange and valves
holes are strict with no leakage. The ESP should be qualified in the strictness test.
5.8.

Before insulate the ash hopper electric heating device, conduct the energizing test first,
making sure every thing is OK, then proceed to finish the outer shell insulation work.
5.9.
ESP is running in HV, so the HV equipments should all be earthed reliably.
5.10.
ESP outer shell and HV rectifier transformer anode cable should be complete and fixed.
5.11.
All the porcelain casings are stable in contact and receive even pressure. Each porcelain
should be kept clean and dry.
5.12.
HV isolating vale actuator is flexible and precise.
5.13.400V
HV isolating vale actuator is flexible and precise.
5.14.

LV operation control devices have passed the energizing test. (The check of alarming
system, rapping circuit, soot removal circuit, heating and temperature probe circuits.)
5.15.
10

Site equipments and systems have been named, numbered and hanged with nameplates.
The operators are in position. All the needed tools, drawings and forms are complete.
5.16.
All the pressure, temperature and flow gauges have been checked qualified and all in
normal operation.
5.17.

5.1
All the pressure, temperature and flow gauges have been checked qualified and all in
normal operation.

6
Commissioning Methods and Steps
6.1

Commissioning steps
6.1.1.
ESP HV power supply device energizing test.
6.1.2.
Break the main circuit switch, and cut off the power, make sure no person inside the ESP
and around the HV silicon rectifier.
6.1.3.
Connect the isolating valve to the electric field position.
6.1.4.
Connect in the main circuit power and switch on the main circuit switch.
6.1.5.
Push the controller operation button and send the equipments in operation.
11

6.1.6.

The primary pressure, primary current, secondary pressure, and secondary current
indications should be change along with the change of the angle of flow.
6.1.7.
5%
The correspondence between the secondary pressure, secondary current indicated value on
the controller and on the secondary gauge should not over 5% after calibration.
6.2
Protection function test
6.2.1
Secondary open circuit protection
6.2.1.1.
Break off the main circuit switch and cut off the power.
6.2.1.2.
Switch the isolating valve to open circuit position.
6.2.1.3.
Connect in the main circuit power and switch on the main circuit switch.
6.2.1.4.
Press the operation button on the controller and send the equipments in operation.
6.2.1.5.
0 70KV

Check the indicative value of the primary pressure and current, secondary pressure and
current on the HV control cabinet. Normally, the primary and secondary current should be
about zero; secondary pressure at about 70KV. After a while the HV control cabinet should
be able to start the secondary open circuit protection trip.
12

6.2.2.
Output short circuit protection
6.2.2.1.
Break off the main circuit switch and cut off the power.
6.2.2.2.
Break off the main circuit switch and cut off the power.
6.2.2.3.
Connect in the main circuit power and switch on the main circuit switch.
6.2.2.4
Press the operation button on the controller and send the equipments in operation.
6.2.2.5.
0 0

Check the indicative value of the primary pressure and current, secondary pressure and
current on the HV control cabinet. Normally the primary and secondary current should not
be zero and the second current is zero. After a while the HV control cabinet should be able
to start the output short circuit protection trip.
6.2.3.
Bias excitation protection
6.2.3.1.
Take off one controllable silicon triggering signal.
6.2.3.2.
Load the equipments with normal load.
6.2.3.3.
Connect in main circuit power source and switch on the main circuit switch.
6.2.3.4.
13

Push the operation button on the controller and keep the equipments in operation.
6.2.3.5. 30%
When the secondary current exceeded 30% of the rated value, the equipments should be
able to start the bias excitation protection trip.
6.2.4.
Controllable silicon open-circuit protection.
6.2.4.1.
Take off two Controllable silicon triggering signal
6.2.4.2.
Load the equipments with normal load.
6.2.4.3.
Connect in main circuit power source and switch on the main circuit switch.
6.2.4.4.

Push the operation button on the controller and keep the equipments in operation. After a
while, the equipment should be able to start the Controllable silicon open circuit protection.
6.2.5.
Output under-voltage protection
6.2.5.1.
Load the equipments with normal load.
6.2.5.2.
Connect in main circuit power source and switch on the main circuit switch.
6.2.5.3.
Push the operation button on the controller and keep the equipments in operation.
6.2.5.4. 25KV
14


Use the stop and down move button on the operation controller and keep the output voltage
under 25KV. After a while, the equipment should be able to start the output under-voltage
protection trip.
6.2.6.
Alarm of critical oil temperature
75 85

The controller should send out the alarm of critical oil temperature when the oil
temperature of the rectifier transformer over 75 but below 85 (simulate with
resistance box).
6.2.7.
Alarm of emergency oil temperature
85

The controller should send out the alarm of critical oil temperature when the oil
temperature of the rectifier transformer over 85 (simulate with resistance box).
6.2.8.
Alarm of light gas

The controller should be able to send out the alarm of light gas when the rectifier
transformer air breaker light gas signal activated.
6.2.9.
Alarm of heavy gas

The controller should be able to send out the alarm of heavy gas when the rectifier
transformer air breaker heavy gas signal activated.

15

6.3.
Static no field boosting test
6.3.1.

The condition for conducting the static electric field boosting test: rapping system and
induced draft fan not in operation, and the electric field is static and no gas or air
admission.
6.3.2. 24
The electric heater should be in operation for 24hrs before the test.
6.3.3.
Block all the manholes of the ESP and hang on the OPERATION sign.
6.3.4.
Start the static no field boosting test stage by stage from the last stage of the field.
6.3.5.
Make sure the main circuit switch off and the main circuit power have been cut off.
6.3.6.
Temporary install static high tension voltmeter at the high voltage side of the rectifier
transformer.
6.3.7.
Under the instruction of the site commander, switch the isolating valve at the field position.
6.3.8.
Under the instruction of the site commander, switch the isolating valve at the field position.
6.3.9.
Push the operation button on the controller and keep the equipments in operation.
6.3.10.

16

Use the button on the control panel to boost the voltage to rated value. Calibrate the
secondary pressure indicative value on the control panel along with the indicative value on
static high tension voltmeter. At the same time, calibrate the secondary ammeter according
to the feed back resistance voltage. After the calibration, lower down the electric field
voltage, and switch off the main circuit switch, and break the isolating blade, earth the
rectifier, take off static voltmeters, and then recover the rectifier transformer output and
isolating blade. Boost the voltage in electric field I with one transformer. Monitoring the
secondary ammeter indicative value till it reached to the rated value, keep the records.

Operations on other filed single transformers voltage boosting the same as operation on
filed I.
6.3.11. 0 5KV

Use the buttons on the control panel, keep one group of secondary voltage and current
when the current not zero and the secondary voltage raise every 5KV. The test finished
when the secondary voltage or secondary current reached the rectified value.
6.3.12.

During the test, record the voltage and current of the field discharge inception and
flashover. Record the current under different voltage of each field and make volt-ampere
characteristics.
6.4.
The boosting test of the two power supply field in parallel

The selection of the capacity of HV Controllable silicon rectifier transformer is based on

the plate and line current density and the voltage puncture value of the ESP under flue gas
flow condition. If the air current density increased because of the no-field boosting test, and
17

one high voltage rectifier transformer not capable of supply for single electric field, that is
secondary current been locked after reached the rated value and secondary voltage cant
reach the filed puncture value, then, two high rectifier transformers with same capacity
could be used to supply power for one field.
6.4.1.
The parallel power supply test should be conducted after the boosting test of one high
voltage rectifier transformer supply one electric field have been succeed.
6.4.2.
500mm
To parallel the two transformers by regulate the phases of the primary powers to be the
same and connect the two transformers by leads with over 500mm discharge separation.
6.4.3.

For the parallel power supply test, two persons are needed to startup and operate the two
control panels at the same time to boost the voltages. If the sum of increased current values
not reached the rated value, continue to boost voltage till the electric field has flash over.
Here the secondary current would be equal to the sum of the two high voltage rectifier
transformer currents. Secondary voltage would be the average value between the two
transformers. Record the voltage ampere characteristics at the same time.
6.4.4. 6
Conduct boosting test for 6 fields.
6.5.
Commissioning of cathode, anode and distribution rapping systems.

For the safety sake, the trail run the cathode, anode and distribution rapping systems should
be conducted before putting the ESP in operation. Make sure the drive and rapping devise
are in good ready to operation condition.
6.5.1.
18

Check before the cold commissioning

6.5.1.1.
Check the hammers and anvils of the cathode, anode and distribution plate be in correct
position. The bearing and hammer could be freely rotated.
6.5.1.2.

Check the rapping speed reduction motor with correct direction, flexible rotating, proper
chain, each lubricating part has been oiled, oil in the redactor is qualified and the oil level
above the intermediate line.
6.5.1.3.
The insulator chamber should be clean with no impurities. The leads are in good contact
and high voltage porcelain vases with no dust.
6.5.1.4.
Make sure no one is inside before closing all the manholes on the proper, in the insulator
chamber and ash hopper.
6.5.1.5.
Put the on-line meters (protection systems, adjusting devices, temperature probe devices,
alarm devices and indicator light) in operation.
6.5.1.6.

The wiring of the rapping motors and earthing leads have been fixed stable. The safety
collar has been installed and has no contact with the rotating parts.
6.5.1.7.
The calibration of ESP control circuit and alarm signals are qualified.
6.6.
Put cathode, anode and distribution rapping systems in operation.
6.6.1.

19

Loose the shaft coupling of the rapping system, hand start the motor, making sure the
direction is correct, measuring the starting current and no-load current.
6.6.2.

Loose the shaft coupling of the rapping system, hand start the motor, making sure the
direction is correct, measuring the starting current and no-load current.
6.6.3.

After the test, recover the shaft coupling, make sure the control cabinet, power distribution
cabinet in good condition. Energize the power of cathode and anode rapping system, hand
start them for trial run. Push the emergency button to stop the system when the motor
reached the full speed. The local personnel should make sure the rapping systems should be
in the correct direction. after the checking finished, restart the rapping systems, record the
starting current and measuring the tri-phase current.
6.6.4.

The rotating parts and bearings are in normal rotating with no abnormal noise. The
temperature of rapping motor and bearing are normal. Reducer has normal oil level with no
oil leakage. The mechanical safety lever has no rupture.
6.6.5.
Regulate the rapping interval according to the different electric field of the ESP.
6.6.6.

During the trial-run, regularly check the rapping shaft rotating, make sure there is no stuck,
and hammer, anvil and rapping are in correct position with no mistake. Observe the oil
level change in the redactor.
6.6.7. 4
The trial-run should last at least 4 hours.
6.7.
20

ESP electric heater energizing test

6.7.1.
Calibrate the heater temperature probe circuit and alarm system, make sure the circuit and
alarms are correct and in good condition.
6.7.2
50M 2000V
Before energizing, the insulation resistance should be tested qualified and the alternative
current voltage withstand test be finished. The insulation resistance should be 50M, AC
voltage withstand test values: AC 2000V, no flashover and puncture for one minute.
6.7.3.
On the heater control panel, put the switch on stop position.
6.7.4.
Switch on the circuit power switch.
6.7.5.
Turn the changeover switch on the Manual position. One heater or motor in continue
operation.
6.7.6.
Put the electric heater in operation, check if there is any open circuit, fast temperature
rising, and make sure the temperature range is correct.
6.8.
Hot startup of the ESP
6.8.1.
Checking before hot startup.
6.8.1.1.
The inlet and outlet gas ducts have finished erection and are ready for operation.
6.8.1.2.
21


heck the insulator chamber should be clean, and the leads contact is good, high voltage
porcelain vase has no dust, and the damping resistance is complete with no damage.
6.8.1.3.
Check the earthing blade mechanism in the insulator room is flexible with no abrasion, and
operate correct.
6.8.1.4.

Make sure no one stay inside the ESP, and strictly block the manholes, electrical insulator
room manholes and ash bucket manholes.
6.8.1.5.

All the equipments and components are complete with clear and correct sign. The joint
surface is close with no leakage. The insulations are complete with clear outlook. The
illumination is adequate.
6.8.1.6.

All the gauges, power switches, protection systems, governor systems, temperature probe
systems, alarm systems and indicator lights are normal, and the power is on.
6.8.1.7.
Inside the LV distribution panel, all the switches and rapping devices are good, all the
power and operating fuses are in good condition
6.8.1.8.
Ash conveying system in operation.
6.8.1.9.
The oil of the rectifier transformer is clear, with no turbidity, no impurity and no leakage.
The oil level is normal.
6.8.1.10.
Boiler flue gas system auxiliary units are in operation.
22

6.8.2
Hot startup of the ESP
6.8.2.1.
Before boiler ignition, put the ash hopper heating device and insulator heating device into
operation.
6.8.2.2.
Before boiler ignition, supply power to cathode and anode rapping system and put them
into continuous operation.
6.8.2.3.

During primary ignition, if put in the high voltage, the oil gas might adhere to the plate and
the wires and cause corrosion, affect the efficiency of the dust removal. Therefore put in the
high voltage after the oil break.
6.8.2.4. 20

30

Heating the insulator to 20 30 above the dew point temperature, then put the
rectifier transformer into operation.
6.8.2.5.

After boiler is changed to full coal combustion, put in the rectifier transformer from the
first electric field. Push the button and auto boost the voltage to the rated value.
6.8.2.6.
Put the continuous rapping device at the program rapping position and at the same time,
stop the operation of the insulator heating device.
6.8.2.7.

Keep patrolling and check the operation of the rectifier transformer, control cabinet, ESP
proper, and rapping systems.
6.8.2.8.

23

During the operation, the dust ducts, manholes should be strict and with no air leakage
6.8.2.9.

Regularly observe the change of secondary current and pressure, master the operation
condition of the ESP for the convenient of in time adjust. At the meanwhile, adjust the
parameters of secondary current and pressure of each filed and the rapping intervals
according to the boiler combustion, coal quality and ash content.
6.8.2.10.
During the operation, its prohibited to enter the energized high tension cell and open the
energized high tension insulator room to check.
6.8.2.11.

The change over of the HV isolating blade should not be under loaded. Stop the high
voltage rectifier for change over; restart it after the changeover.
6.9.

Outage of the ESP

6.9.1
Stop the operation of the rectifier transformer.
6.9.1.1.
Push the stop button on the HV control panel and stop the rectifier transformer.
6.9.1.2.
Turn the key switch on the rectifier transformer control cabinet to open position.
6.9.1.3. 380V
Cut off the HV control cabinet 380V power switch.
6.9.1.4.
Cut off the high voltage control panel operating power.
24

6.9.1.5.
Switch the HV isolating blade at the earth position
6.9.2.
Put the rapping system in continuous operation.
6.9.3. 8
Stop the rapping system after the boiler stop operation for 8 hours.
6.9.4.
Stop the ash hopper heater after the hopper confirmed has no ash. hours.
6.9.5.
When the boiler is emergency stopped and combustion extinguished, stop the rectifier
transformer at once.
6.9.6.
Stop the HV rectifier transformer, first lower the voltage to zero, and then push the stop
button.
6.9.7.
Boiler stop for short time, the insulator chamber, ash hopper heater should go on operation.

7
Commissioning Quality Check standard
7.1.
The rotating parts and bearings of the cathode and anode rapping devices are in good
operation condition and with no noise.
7.2.
Rapping redactor bearing temperature is in normal operation with no oil leakage, the chains
are in proper tensity.
7.3. ,
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No abrasion in the rapping bearings. And the hammer position is correct.

7.4.
The rectifier transformer is in normal operation with no oil leakage or over temperature.
7.5.
The HV power supply devices are in normal operation and the protection functions are
correct.
7.6.
No air leakage to the ESP proper, gas duct, manholes and so on.
7.7.
The control circuits, indicator lights, signal lights, alarms are in normal operation.

8
Commissioning Records
8.1
The problems and solutions in commissioning.
8.2 ,
Relevant inform bills, and design deviation bills.

9
Organization and Divisions
9.1

Erection unit takes charge in organizing partial trial run, supervising equipments, supplying
and cutting power, removing defects, lighting, establishing scaffolds and erecting
temporary facilities.
9.2
Produce unit takes charge in starting and stopping equipments, regulating running and
handling accidents as operation regulations and the procedure required.
26

9.3

Commissioning unit takes charge in compiling trial run measures (procedures), technology
instructing, recording, collecting and analyzing data and compiling commissioning reports.
9.4
Manufacturers take charge in test and adjustment on site.
9.5

During test, clear each unit contacts and according to site situations, each unit appoint
proper person for cooperation.

10
HSE Control Measures
10.1. 400V

From the application of the energizing test on, the ESP transformer 400V switches should
be regarded as energized, and no one should touch them.
10.2.

When energizing the primary equipments, special personnel should be on watch, and stop
the test at once if any abnormity be found. Continue the test, after the causes be found and
eliminated.
10.3.

The test should be united leaded. No tester should change the procedures with out
permission. If changes needed, report to the commanding personnel, and after permitted,
operate under the command.
10.4. , ,
Mark the energized equipments; put isolating devices between energized equipments and
equipments under construction.
10.5.
27

During the static no-field boosting test, special personnel must be sent to watch over the
HV rectifier transformer operation.
10.6.

Static HV voltmeter outer shell should be firmly earthed. And the high voltage testing area
should have effective isolating devices and be enclosed by red-white band.
10.7.
Send security personnel to guard the ESP boosting testing area, and no outsider should
enter it.
10.8. , 6kV
,
Lock the energized switch room. The operators should strictly follow the work bill system.
The 6KV switch room should be prepared with safety appliance, such as: insulating gloves,
insulating shoes, special earthing leads, high voltage electroscope.
10.9.
Reclaim all the used batteries produced during the energizing process, to protect the
environment.
10.10.

Keep the fire-fighting devices in good condition. The fire-fighting appliance should be in
reasonable places and with clear marks. Relevant fire-fighting and security personnel are in
position.
10.11.
To avoid the high voltage electric shock, its prohibited to open the manholes if the ESP in
operation.

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