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Boiler Ash Handling System Commissioning Procedure

Document No

PROJECT

OWNER

OWNERs
ENGINEER

EPC
CONTRACTOR

CONTRACTOR
s ENGINEER

2150MW
300 MW(2150MW) Coal Fired Power Plant at Maamba, Zambia

Maamba Collieries Limited

TATA
TATA CONSULTING ENGINEERS LIMITED

SEPCO ELECTRIC POWER CONSTRUCTION CORPORATION

SHANDONG ELECTRIC POWER ENGINEERING CONSULTING


INSTITUTE CORP., LTD


Catalogue
1..............................................................................................................................3
Overview.......................................................................................................................3
2.....................................................................................................3
Main equipment technique specification....................................................................3
3.......................................................................................................17
Commissioning basis and standard..........................................................................17
4...................................................................................................................17
Commissioning purpose.............................................................................................17
5...................................................................................................................18
Commissioning range.................................................................................................18
6..........................................................................18
Commissioning condition and checking content.....................................................18
7..........................................................................................18
Commissioning process, procedure and method.....................................................18
8......................................................................................24
Commissioning quality targets and assess standards.............................................24
9..........................................................................24
Environment, occupational health and safety control procedure..........................24
10.................................................................................................................26
Organization and division.........................................................................................26
11......................................................................................................................28

Appendix.....................................................................................................................28
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 ash removal system
commissioning.
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

Unit

BMCR

BECR


Main steam flow

Main steam pressure

Main steam temp.

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

T/H

510

485.73

MPa

14.32

14.32

540

540

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

Coal quality analysis:


Description
ProximateAnalysis(ADB)
Ash
Volatile Matter (ADB)
Fixed Carbon (ADB)

Range of Coal
Analysis
%
%
%

45.3 to 53.27
19.6 to 18.05
33.7 to 27.47

Coal Analysis
Performance
Worst
48.3
18.8
31.55

53.27
18.08
27.44

Inherent Moisture (ADB)


%
Total Moisture
%
Normal Heating Value
Kcal/kg
UltimateAnalysis(as received basis)
Carbon (C)
%
Hydrogen (H2 )
%n
Nitrogen (N2)
%
Oxygen (O2)
%
Sulphur (S)
%
Moisture (H2O)
%
Ash
%
Gross calorific value (as received
Kcal
basis)
/kg
Hard grove index
HGI
Ash Analysis
Silica (SiO2)
%
Alumina (A12O3 )
%
Iron Oxide (Fe2O3)
%
Titanio (TiO2)
%
Phosphoric Anhydride(P2O5)
%

1.4 to 1.21
1.9 to 2.1
4059 to 2990

1.35
1.9
3500

1.21
2.1
3110

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

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

2.2
Ash removal system regulation and main equipment technique data
2.2.1
Ash removal system regulation:

MCR 230%
1
Ash removal system adopts positive pneumatic dense phase ash conveying
system, which the conveying capacity is not less than 230% ash discharging quantity
under MCR working condition. Dust precipitator is single channel ESP, each hopper
of precipitator and APH is provided with one set of pneumatic pump.

2 7 14
2

2120m3 31.8m
Precipitator hopper is provided with gasification air system, matching with
gasification air fan, electric heater and hopper gasification plate. 2 public ash silos are

matched for two boilers, and each boiler is provided with 7 ash pipes, total 14 for two
boilers. Each ash pipe can be converted between two ash silos through change-over
valves on silo top. The design can satisfy two boilers operation simultaneously, or
single boiler operation, and two boilers ash removal systems will not affect each other
and guarantee the output. Volume of reinforced concrete ash silo is 2120m 3, with top
height of 31.8m.

~25%

Gasification device is installed at bottom of ash silo, and ash removal box,
exhaust filter (bag dust collector), pressure vacuum release valve, level gauge and
other equipment are installed on ash silo top. Two ash removal mode are used under
each ash silo with three dumping outlets, in which the first outlet to discharge dry ash
to tank truck to outside users; the second to discharge dry ash to humidification mixer
to produce wet ash with 25% water content, which is also used by outside user; the
third is standby.
1
234

Pneumatic ash removal system including following sub-system: (1) precipitator


(including APH) fly ash conveying system; (2) control air usage system; (3) system of
top discharging, exhaust and level indication; (4) control system of pneumatic system.
2.2.1.1
Precipitator fly ash conveying system
()

Precipitator fly ash conveying system (including APH) is designed as one boiler
as a unit, from under outlet flange of precipitator and APH hopper to inlet flange of
silo top discharging box, including silo and pump assembly (pressure conveying
device), pneumatic conveying pipe, pipe change-over valves, pipe expansion joints,
pipe blowing devices, etc.
2.2.1.2

Control air usage and bag pulse cleaning air usage system

Used air by pneumatic elements and bag pulse cleaning of top exhaust filter is from
compressed air center of the plant for instrument system.
2.2.1.3
System of silo discharging, exhaust and level indication

Including silo top discharging box, silo top exhaust filter (bag dust collector), pressure
vacuum releasing valve, silo top pipe change-over valves, level gauge and other
equipment and accessories.
2.2.1.4 PLC
Control system of pneumatic ash removal system (except PLC control cabinet)

All magnetic valves box and monitoring instrument required by the entire pneumatic
ash removal control system. All equipment can be controlled locally by auto and
manual, also controlled in control room by remote, and local control can lock the
other control modes.

Ash and slag quantity

Coal category

Unit capacity
(t/h)

Design coal

Checking coal

1150

(t/h)
Ash quantity per hour

Ash
Slag
Ash and slag
44.02
44.02
88.04

2150

88.04

88.04

176.08

1150

53.59

53.59

107.18

2150

107.18

107.18

214.36

1. 50% 50%
Note: slag quantity is calculated as per proportion of 50% of total ash and slag,
as well as ash.
2. q4 4.27%
Mechanical imperfect combustion loss: q4 4.27%
3. 3%
Sulfur ARB: 3%

Ash quantity of single boiler with two precipitators

Discharging point

Hopper
quantity

Precipitator
electric field

Precipitator
electric field

Precipitator
electric field

Precipitator
electric field

Precipitator
electric field

Precipitator
electric field

APH hopper

22

Ash quantity of each Ash quantity of each


hopper by design coal
hopper by checking
coal
6.47 4=25.88
9.266 4=37.064

22

1.731 4=6.924

2.48 4=9.92

22

0.4556 4=1.822

0.6525 4=261

22

0.2734 4=1.0936

0.3915 4=1.566

22

0.1367 4=0.5468

0.1958 4=0.7832

22

0.04556 4=0.1822

0.06525 4=0.261

0.911 4=3.644

1.305 4=5.22

II

III

IV

VI

2.2.2

Main equipment technique data of ash removal system

APH pressure conveying device



Type

Inlet diameter

Capacity per set

Outlet diameter

Silo and pump assembly height



Design pressure

Working pressure

Device weight

Output

Working temperature

Usage temperature range



Material
/
Transmitter inner diameter/wall thickness

Pump thickness

Manufacturer

6.0E/8
DN200
0.20 M3
DN100

Including compensator, rectangle-circle


connector, manual pneumatic valves
1.0 MPa
0.35 MPa
610 Kg
6.003t/h
400
0-380

Ductile cast iron


0.58m/18mm
18mm

Clyde

Pressure conveying device of electric field fly ash (filling for various fields)

Conveying pump

Type

Inlet diameter

Capacity per set

Outlet diameter

Design pressure

Device weight

Output

Working temperature

Usage temperature
range

Material

Service life of pump


(pressurized
components)
(considering
abrasion)

Gasification plate
material of
transmitter

Gasification plate
service life of
transmitter
/
Transmitter inner
diameter/wall

I field
80/8

II field
80/8

III field
9/8

IV field
8.0/8

V field
8.0/8

VI field
8.0/8

DN200

DN200

DN200

DN200

DN200

DN200

2.50

2.50

0.33

0.30

0.30

0.30

DN150

DN150

DN150

DN150

DN150

DN150

1.0MPa
0.35

1.0MPa
0.35

1.0MPa
0.35

1.0MPa
0.35

1.0MPa
0.35

1.0MPa
0.35

1300Kg
85.24t/h

1300Kg
22.81t/h

750Kg

710Kg

710Kg

710Kg

6.003t/h

3.602t/h

1.801t/h

0.6t/h

150

150

150

150

150

150

0150

0150

0150

0150

0150

0150

16MnR

16MnR

16MnR

30
30 years

30
30 years

30
30 years

Ductile
cast iron
30
30 years

Ductile
cast iron
30
30 years

Ductile
cast iron
30
30 years

No

No

No

No

No

No

No

No

No

No

No

No

8mm

8mm

6mm

15mm

15mm

15mm

thickness

Pump thickness

Manufacturer

Quantity

8mm

8mm

6mm

15mm

15mm

15mm

Clyde
8

Clyde
8

Clyde
8

Clyde
8

Clyde
8

Clyde
8

120.06t/h
System output for each boiler: (system output: 120.06t/h)

Hopper conveying pipe output of I field

Hopper conveying pipe output of II field

Hopper conveying pipe output of III field

Hopper conveying pipe output of IV field

Hopper conveying pipe output of V field

Hopper conveying pipe output of VI field

Hopper conveying pipe output of APH

85.24th
22.81-85.24th
6.003-22.81th
3.602-6.003th
1.801-3.602th
0.6003-2.401th
6.003th

120.06t/h
Average proportion of conveying ash and air (system output: 120.06t/h)

Proportion of conveying ash and air of I


field

Proportion of conveying ash and air of II


field

Proportion of conveying ash and air of III


field

Proportion of conveying ash and air of IV


field

39.7

kgkg

39.7

kgkg

31.7

kgkg

31.7

kgkg


Proportion of conveying ash and air of V
field

Proportion of conveying ash and air of VI


field

Proportion of conveying ash and air of


APH field

Proportion of conveying ash and air of


each boiler

31.7

kgkg

31.7

kgkg

30.1

kgkg

38.2

kgkg

Expansion joint under hopper

Mode and type



Quantity

Specification

Design pressure

Temperature tolerance

Material

Compensation

Manufacturer

I field

II field

Fields of III, IV,


V and VI

No

APH

Flexible
joint
8

Flexible
joint
8

DN200

DN200

Normal
pressure
200

Normal
pressure
200

Stainless
steel
40mm

Stainless
stee
40mm

Clyde

Clyde

Transition rectangle-circle connector

No

I field

II field

APH

200x200DN200
Q235

Fields of III, IV,


V and VI
8/
8 per field
200x200DN200
Q235


Quantity

Specification

Material

Manufacturer

200x200DN200
Q235

Clyde

Clyde

Clyde

Clyde

4
200x200DN200
Q235

Pneumatic dome valve

Mode and type



Specification

Driving mode

Valve body
material

Valve plate
material

Seal ring
material

Seal ring type

Manufacturer

Quantity

I field

II field

Pneumatic
dome valve
DN200

Fields of III,
IV, V and VI

Pneumatic
dome valve
DN200

Pneumatic
dome valve
DN200

APH

Pneumatic
dome valve
DN200

Pneumatic

Ductile cast
iron

Ductile cast
iron

Special rubber

Pneumatic

Ductile cast
iron

Ductile cast
iron

Special rubber

Pneumatic

Ductile cast
iron

Ductile cast
iron

Special rubber

Pneumatic

Ductile cast
iron

Ductile cast
iron

Special rubber

DN200

DN200

DN200

DN200

Clyde
8

Clyde
8

Clyde
8/
8 per field

Clyde
4

Silo pump discharging valve

I field

II field

III field

Mode and type

No

No

No


Specification

Driving mode

Valve body material

Valve plate material

Seal ring material

Seal ring type

Manufacturer

Quantity

Fields of IV, V
and VI

Pneumatic dome
valve
DN150

APH

Pneumatic

Ductile cast iron

Ductile cast iron

Special rubber
DN150

Clyde
6

No

Pneumatic air admission valve, including silo pumps various valves and
components (including air admission components on main ash conveying pipe and
discharging pipe)

Mode and type


Quantity

Driving mode

I field

II field

Pneumatic
butterfly
damper
4

Fields of III,
IV, V and VI

Pneumatic
butterfly
damper
8

Pneumatic
butterfly
damper
4

Pneumatic

APH

Pneumatic
butterfly
damper
2

Pneumatic

Pneumatic

Pneumatic


Specification

Valve body
material

Valve plate
material

Seal surface
material

Manufacturer

DN65

DN65

DN50

DN50

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Cast steel

Hard seal

Hard seal

Hard seal

Hard seal

Clyde

Clyde

Clyde

Clyde

Pneumatic exhaust valve, including various valves and components of silo pump
exhaust components, classified by use in different ESP and filled as per different pipe
diameter and pressure.

I field

Mode and type Pneumatic dome


valve
8

Quantity

Driving mode
Pneumatic
DN80

Specification

Valve body
Ductile cast iron
material

Valve plate
Ductile cast iron
material

Seal ring
Special rubber
material
20000

II field

Fields of III,
IV, V and VI

No

APH

Pneumatic
DN80

Ductile cast iron

Ductile cast iron

Special rubber

20000

Pneumatic dome
valve
8

No

Service life of
valve body
and plug

Manufacturer

Clyde

Clyde

Silo pump discharging pipe isolation valve

Mode and
type

Quantity

Driving
mode

Specification

Valve body
material

Valve plate
material

Seal ring
material

Manufacturer

I field

II field

III field

Damper
valve
2

Damper
valve
2

Damper
valve
2

Manual

Manual

DN150

Fields of, IV, V


and VI

Damper valve

APH

Damper valve

Manual

2/
2 per field

Manual

Manual

DN150

DN150

DN150

DN125

Cast
iron

Cast
iron
--

Cast
iron

Cast
iron
--

Cast
iron

Cast
iron
--

Cast iron

Cast iron

Cast iron

Cast iron

--

--

Clyde

Clyde

Clyde

Clyde

Clyde

Discharging valve

Mode and

I field

II field

III field

Ball valve

Ball valve

Ball valve

Fields of, IV, V


and VI

Ball valve

APH

Ball valve

type
4
4
2

Quantity

Driving
Pneumatic Pneumatic Pneumatic
mode
DN50
DN50
DN50

Specification

Valve body
Cast steel Cast steel Cast steel
material

Valve plate
Cast steel Cast steel Cast steel
material

Seal surface
Alloy
Alloy
Alloy
material
steel
steel
steel

Seal ring
No
No
No
material

Manufacturer
Clyde
Clyde
Clyde

Pneumatic

Pneumatic

DN50

DN50

Cast steel

Cast steel

Cast steel

Cast steel

Alloy steel

No

Alloy
steel

No

Clyde

Clyde

3.
Commissioning basis and standard
3.1
Relevant contracts, design drawings, manufacture introduction, technique agreement
and other documents
3.2
Relevant regualtion and rules of state and industry
3.3 MCL 2150MW
Commissioning outline of Zambia MCL 2150MW coal fired power plant project
4.
Commissioning purpose
4.1

Check all equipment manufacturing and erection quality of boiler ash removal system.
4.2
Check electric and I&C protections interlock and signal devices, and confirm the
action reliability.
4.3
Check system and equipment operation, test system performance, check out and
eliminate the possible failures.
4.4

Guarantee all equipment in normal condition and safe, stable and economic operation
through ash removal system commissioning.
5.
Commissioning range

Ash removal system commissioning including: valves open/close check, static


interlock protection test and alarm test of equipment, equipment dynamic interlock
protection test, system interlock protection test, equipment static and dynamic
startup/shutdown test, ash removal program test, ash removal system tightness test,
dynamic operation of ash removal system
6.
Commissioning condition and checking content
1

Before system commissioning, the provided condition as per content of


(appendix 1: condition checking list before integral startup) shall be checked
completely by commissioning staffs, with recording.
7.

Commissioning process, procedure and method


7.1
Commissioning procedure of ash removal system

2
3
4
5
6

Technique handover

Condition
commissioning

confirm

before

1. System
pipe
and
equipment
erection are completed, with
complete recording.
2. I&C and electrical instruments
erection
are
completed,
calibration is qualified, and it
can put into operation.
3. Single commissioning of system
equipment is qualified.

System valve driving test

System dynamic and static interlock test

Tightness test by starting air compressor

1. Air single protection test,


cold dryer single protection
test;
2. Ash hopper gasification air
fan
interlock
protection
test;
3. Ash cellar gasification air
fan
interlock
protection
test;
4. Ash
removal
water
pump
interlock protection test;
5. Startup/shutdown
test
of
system equipment;
6. Static test of ash removal
system

Dynamic program commissioning

Commissioning flow chart


7.2
Commissioning procedure and method of ash removal system
7.2.1
Open/close test of actuators
7.2.2 PLC

Open/close or change over ash removal valves through PLC to confirm local action
correction and flexibility. Channel check for important I&C signal points.
7.2.3
Gasification air system test of ash hopper:
1 1
Operation mode: one in operation and one in standby

Electrical heater startup condition: gasification air fan in operation

Gasification air fan shutdown condition: electrical heater shutdown

Gasification air fan trip, interlock shutdown electrical heater

When operating air fan trip caused by failure, interlock open standby air fan
outlet motor valve and alarm, start standby air fan.
7.2.4

Gasification air system of ash silo:


2 1
Operation mode: 2 in operation and 1 in standby

Electrical heater startup condition: gasification air fan in operation

Gasification air fan shutdown condition: electrical heater shutdown

Electrical heater trip, interlock shutdown Gasification air fan

When operating air fan trip caused by failure, interlock open standby air fan
outlet motor valve and alarm, start standby air fan.
7.2.5
Ash removal air compressor system
10 2
Operation mode: 10 in operation and 2 in standby
10
If pressure is low when 10 in operation, interlock start standby air compressor.
7.2.6
Cold dryer system
6 2
Operation mode: 6 in operation and 2 in standby
6 ,
When six sets in operation and one is trip by failure, interlock standby cold
dryer (firstly open outlet motor valves).
7.2.7

Ash removal startup


a.:
startup procedure of ash removal system
20
20 hours before boiler firing, put electrical heater of precipitator hopper;
72
100
72 hours before ash silo receiving ash, put ventilation to dry and open all
gasification valves of ash silo to maintain gasification air temperature at
100 by put one set of gasification air fan and one heater into operation.

Check that lube oil, cooling water, dryers and other parts of air compressor
system shall conform to startup requirement; reversely operate air conveying
system as per regulated sequence, firstly start one cold dryer and then start air
compressors one by one.

Filers and gas tanks of started air compressors shall be cleaned up without
deposited water.

Air source pressure of conveying and control systems shall be regulated to


satisfy pressure of ash silo pump and pipe operation, and gas tank pressure
shall meet design requirement.

Put bag filter of ash silo, air source and bag vibration shall be checked and
normal.

All hoppers, ash silo pumps, level gauges and heaters shall be checked,
which shall be at auto control position.

Manual butterfly valve of ash hopper shall be checked at closing position, put
positive pressure ash conveying system compressed air blowing into
operation; each group of ash silo pump shall be blown one time by manual,
and then put auto ash cleaning program into operation, after at least three
circulation, then into ash conveying operation.

I/ ,

Open manual butterfly valve of ash hopper, and put ash silo pump into
operation; as per principle of firstly less ash and then more ash, put ash
hopper pump of economizer, ash hopper pump of denitration, ash hopper
pump of ESP I/II field and ash hopper pump of bag dust collector into
operation.

When ash pumps into operation, check ash flow condition at all time, and
hammer it when it is necessary; if ash blocking is appeared, close inlet ash
valve and convert to compressed air blowing operation.
8

Before silo ash storage, all gasification pipes shall be checked without
blocking, and pipe temperature is a little hot; ash discharging shall be carried
out after 8 hours continuous storage to prevent deposit at silo bottom;
according to requirements of truck loading, put dry and wet ash discharging
devices, and one wet pump shall be started firstly before wet ash discharging
into operation.
b.
Shutdown sequence of ash system

After boiler blowing out, shutdown ash pump one by one until all ash in
hopper is completely evacuated according to ash deposit condition.

Deposit ash in silo shall be discharged completely.
60

If gasification air fan system is required to shutdown, firstly shutdown


electrical heater to wait for temperature falling under 60, and then
shutdown gasification air fan system.

Air compressors shutdown can be carried out as per system requirements.
8.
Commissioning quality targets and assess standards
8.1
Unit general startup requirements satisfied.
8.2

Commissioning professional and supervisor shall enforce check and control for key
points of commissioning quality, and report to higher level leader when find out
problems to coordinate and solve to ensure successful startup commissioning.
9.
Environment, occupational health and safety control procedure
9.1

The system shall be organized and commanded coordinately, any change by personnel
is forbidden. The commissioning shall not affect unit safety, if any event that may
affect the unit safety and stability, stop commissioning at once and recover stable
operation of the unit. When the unit is confirmed in stable condition, restart
commissioning again. The commissioning shall be organized and commanded under

headquarter.
9.2

All commissioning staff shall strictly carry out Safety Regulation and on-site relevant
safety regulation to ensure the commissioning safety and reliability.
9.3

If find out abnormal condition during commissioning, timely regulate and report to
leader; if exists possibility that may endanger personnel and equipment, stop
commissioning at once or shutdown the unit when it is necessary.
9.4
If abnormal situation happens during the commissioning, instantly adjust it and report
it to headquarter.
9.5
Professionals shall be on site during the commissioning to ensure the safety of
running equipment and personnel.
9.6
When carry out equipment maintenance, relevant safety measures and working orders
shall be necessary.
9.7

Before ash silo to store ash, it shall be dried completely. Before silo pump starting,
ash hopper fluidization shall be checked to guarantee when ESP into operation, the
fluidization device shall be followed into operation.
9.8

When ash silo in operation condition, working condition of bag filter shall be checked
at all time to prevent deposit, which will cause high back pressure of ash silo to block
ash conveying pipe.
9.9

When system no-load, hopper blocking and other alarm signals does not work, timely
change to manual control and check whether exist ash deposit in all units in order to
handle.

9.10
When check and measure ash pipe and pumps, change to manual operation.
9.11

Working staffs and operators engaged in startup commissioning shall be familiar with
process flow and relevant technique standard of ash removal system.
10.
Organization and division
10.1
EPC unit
10.1.1
In charge of compiling commissioning report.
10.1.2
In charge of the system isolation and closing.
10.1.3
In charge of maintenance, overhaul and troubleshooting of commissioning equipment.
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 check and acceptance after subsystem commissioning.
10.1.7
10.2
Commissioning unit
10.2.1

In charge of compiling commissioning procedure and technique handover.


10.2.2
Prepare relevant measuring instrument, apparatus and tools.
10.2.3
Engage in subsystem commissioning.
10.2.4
In charge of test data recording and filing.
10.2.5
Engage in check and acceptance after subsystem commissioning.
10.2.6
In charge of compiling commissioning report.
10.3
Consultant unit

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

11
Appendix
1
Appendix 1: Checking list before commissioning condition

Checking list of commissioning condition




Class No.
Item

machine

4
5

Commissioning procedure has been


compiled with complete approval
procedure.

()
Erection is completed; secondary grouting
is completed; relevant pipes (including
suspension) erection is completed.

Commission equipment is complete with


necessary nameplates; system connection
is complete.

Cooling and sealing system are complete.

Lube oil quality is qualified with normal


level.

Auxiliaries (such as oil station and valves)


commissioning of large rotation machines
shall be qualified and approved.

System manual, motor and single


commissioning shall be completed with
approval sheet.

Rema
Time
Resu rk
lt

10

11

12

13

14

electrical

15

16

17

18

Pipe blowing and flushing shall be


completed, pipe pressure test shall be
completed with approval sheet.
,

Calibration of safety valves and pressure


release valves of system shall be correct
with recording.

Coupling connection and protection shield


of rotation machine shall be complete.

No-load turning of rotation machine shall


be flexible.

Rotation machine centering shall be


completed with recording.

If exist possibility of reverse running, if


adopts reliable braking measures.

Electrical switch insulation shall be


qualified and recorded.

Electrical switch driving test shall be


completed and qualified with approval
sheet.

Electrical erection, cable laying, blocking


and connection shall be completed.

Cable and motor insulation test shall be


completed, qualified and recorded.

The ground connection shall be qualified.


The motor ground connection strap and
bolt shall be qualified. The connection
section area from strap to ground shall be

19

20

21

I&C

22
23

24

25

26

27

other

28

29

30

31

qualified.

Electrical protection driving test shall be


completed, with correct action and
constant value, and recorded.

Confirm that electrical protection has been


put into operation.

I&C equipment, signal and instrument


pipe shall be completed.

I&C measuring points shall be completed.

I&C, electrical measuring points driving


shall be correct and recorded.

Instrument and meter calibration shall be


completed, with correct measuring range,
and recorded.

I&C logic and protection driving shall be


normal with approval sheet.

All I&C protection constant value shall be


correct with protection.

Equipment and system temporary name


plates shall be completed.

Commissioning tools and material shall


be sufficient.

All professionals shall be on duty, safety


and technique handover shall be carried
out.

Commissioning communication facilities


shall be complete with qualified
communication.

Recording sheet shall be completed.

Environment shall be cleaned up; scaffold


that may affect the commissioning shall
be removed; ground and site shall be
cleaned without sundries.

Commissioning passageway shall be


unblocked with sufficient illumination.

Holes and ditches cover plate, platform,


stair and handrails shall be completed.

Firefighting facilities in commissioning


area shall be put into operation, or
temporary facilities shall be provided.

32

33

34

35

Responsible person of commissioning unit:

Responsible person of consultant unit:

Responsible person of EPC unit:

Date: