Station: NTPC- Simhadri BHEL Ref No.

PS-DC-186-500-0036
Sheet 1 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SLNO
LIST OF CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PERECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

10.0 APPENDICES

a) DRAWINGS

b) LOG SHEET
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 2 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

1.0 PLANT DETAILS

Rotary Air Preheaters supplied are of Bi-Sector type and

Separate APH are given for Primary & secondary Air Circuits.

Rotary Air- Preheater generally comprises the following.

1.1 A.C Driven Motor 2 No

1.2 Air Motor 1 No

1.3 Drive Gear Box.

1.4 Rotating elements with support and guide bearing arrangement

with forced lubrication system.

1.5 Soot blower system.

1.6 Fire Sensing device.

1.7 Deluge system

1.8 Water wash system

1.9 Observation ports and light arrangement

1.10 Rotor stoppage alarm

1.11 Plant item completion list for Mechanical, Electrical and C & I are
to be prepared at site.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 3 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

1.12 For the following system, drawings are enclosed in Section 10.0

a. Guide Bearing Lub-oil System

b. Support Bearing Lub-oil system

c. SB swivel arm sweep

d. Deluge system

e. Water wash system

f. Air Supply to Air Motor

2.0 OBJECTIVE

To commission the rotary air preheater and make it available for

commissioning and operation of the main plant.

3.0 PROPOSAL:

Commissioning of the rotary air preheater is proposed in the

following steps.

3.1 Acid cleaning & oil flushing of Lub-oil system of support & Guide
bearings.

3.2 Trial Run of Main Drive Motors for 8 Hrs.

3.3 Trial run of APH through main motor for 4 Hrs.

3.4 Commissioning of Air Motor and APH operation for 10 minutes

through Air Motor.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 4 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

3.5 Commissioning of soot Boiler system

3.6 Flushing of Deluge and Water wash system.

4.0 SERVICES REQUIRED:

4.1 Availability of manpower with required Tools for attending to any

leak, cleaning of filters.

4.2 Availability of operating personnel to co-ordinate the activities.

4.3 Availability of lighting arrangements and communication in the

operating floors.

4.4 Availability of portable fire fighting equipments near test area.

4.5 Availability service water

4.6 Availability of L.T supply

4.7 Availability of Equipment cooling water.

5.0 SAFETY PRECAUTIONS:

5.1 Debris in and around APH shall be removed

5.2 Approach / stair case / platform wherever required are made

available.

5.3 Man hole doors kept open for inspection should be clearly
guarded from any unauthorised persons entering in to APH. (Test
team leader to ensure this)

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 5 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

5.4 First aid test available near test area.

5.5 Operation of local start / stop PB are ensured for perfect

operation to facilitate stopping of APH in case of necessity.

6.0 EMERGENCY PROCEDUES:

6.1 The test team should be aware of the procedure to be adopted in

case of damage to machinery of injury or any personnel
connected to the activity.

6.2 The test team should be well aware of procedures to be adopted

in case any abnormality in the activity.

7.0 STATE OF THE PLANT:

7.1 APH and its associated system are erected as per recommended
drawing.

7.2 Acid cleaning of support and guide bearing Lub-oil line

completed. No. PS-DC-186-500-0013A)

7.3 All local instrumentation of Lub-oil system completed.

7.4 Power supply system for the pumps are commissioned and
available for operation.

7.5 Instrument and service Air is available upto APH.

7.6 Cooling water for support and guide bearing lub oil pumps is
available for operation. (Equipment Cooling water System)

7.7 Required local / remote I & C inputs for APH are made available.
(List to be mutually prepared at site).
Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 6 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

7.8 Deluge and water wash lines are erected upto APH and drainage
facility is ensured.

7.9 APH fire sensing device commissioned and kept ready for
operation.

7.10 Soot blower and its connected piping are erected and kept ready
for operation. Ensure either steam or air (temporary source) is
made available for commissioning APH during APH start up till
main steam source is made available.

7.11 Oil in support and Guide bearings and fluid coupling are filled up
with recommended oil up to correct level. (Refer O & M Manual).

7.12 All erection log sheets are filled and signed by concerned
agencies

7.13 Flue gas ducts and Air ducts (Primary, Secondary) connections
to APH are completed and ducts are cleared for any loose
material or debris. Expansion bellows connected to APH should
be checked for removal of all temporary braces.

7.14 Dampers at inlet and outlet of APH (Primary of Secondary and

flue gas ) are made free and connected to its drive. All loose
materials / debris lying on the dampers are cleared.

7.15 Main motors (AC-2 Nos) are kept decoupled from fluid coupling.

7.16 Service air line connection to Air Motor is complete with lubricator
cum Regulator.

7.17 Fillers in the lub-oil system cleaned and put in position.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 7 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

7.18 Oil level in the main gear drive ensured up to its normal level.
Local instrumentation of the gear drive completed.

7.19 Insulation of APH should be completed in all respect before boiler

light up with special attention given to Guide bearing area.

7.20 Platforms, Ladders and other structures around APH are

inspected and thermal expansion of APH casing in all direction
ensured.

7.21 Aluminium finger tabs sets installed after seals are set to the
specification.

7.22 Air Seal cover and water shield of support bearing and air seal
cover of guide bearing are erected as per drawing.

7.23 Hot end tracking arrangements are mounted properly and the
system is free to move.

7.24 Breathers of bearing are checked for clean condition.

7.25 Light assembly and observation ports are in position and wired.

7.26 Adjuster nuts of sector plates are fully tightened and locked to
specification

7.27 Lock nuts of axial seal plate adjusters are fully tightened.

7.28 Entire APH plant inspected and ensured that all loose material
are removed and all personnel are away from rotating equipment.

7.29 All man hole doors are closed except one or two as decided by
the test team leader.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 8 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

8.0 METHOD:

8.1 Acid cleaning and Oil Flushing of lub-oil system of support

and Guide Bearing system.

8.1.1 After completing the erection of the lub-oil system, oil lines are
dismantled and acid cleaned following the steps given in the
procedure No. PS-DC-186-500-0013A.

8.1.2 Motors of Lub-oil system are decoupled from pump and after
ensuring Insulation resistance at satisfactory level, motor started,
direction of rotation checked and put on 4 Hrs trial run. No local
current measured during this trial run.

8.1.3 After completion of motor trial run, both pump and motor are
coupled.

8.1.4 Pump primed sufficiently and then started and ensured that the
entire system is filled and oil circulation established. (In the case
of lub-oil system of both guide and support beaning, the bearing
itself is the oil reservoir and oil circulated back to Bearnigs
through filler and cooler) Leaks attended if noticed during oil
circulation.

8.1.5 Initially, the filters in the System are closely observed in terms
increase in pump discharge pressure and filters are cleaned.
Normally, the pump discharge pressure will be around 2.0 KSC to
3.0 KSC and if an increase of around 1 KSC is observed, it
indicates chocking of the filter and requires cleaning.

8.1.6 Continue oil flushing till the pump discharge pressures stabilises
for a period of 4-6 Hrs.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 9 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

8.1.7 After completing the oil flushing, the filters are cleaned again and
put back in to the system.

8.1.8 Relief valve in the pump (or mounted in the discharge line) are
set at 2.0 KSC above the normal operating pressure of the lub-oil
system.

8.1.9 For safety reasons, the oil flushing activity to be performed during
day time.

8.2 Air pre Heater (With Main & stand by Motor)

8.2.1 After ensuring the insulation resistance of the motor at

satisfactory level, motor bumped and direction of rotation
observed. After correcting the direction of rotation, if found
necessary, the motor put on 4 Hrs trial run. Motor no load current
and vibration are noted once during the trial run.

8.2.2 Step 8.2.1 to be repeated for both main and standby motor of
APH gear drive assembly.

8.2.3 After completion of motor trial run, motors are coupled to APH
main gear drive through fluid coupling.

8.2.4 Start the lub oil system of guide and support bearing assembly
and establish circulation.

8.2.5 Start the main motor and stop it after about 10-20 secs to
observe for its normal running. Any abnormal sound noticed to be
brought to the notice of the team leader.

8.2.6 Start the main motor again and allow APH to continonsly run.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 10 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

8.2.7 Observe of

a) Load current (To be logged)

b) Vibration of motor and gear unit (To be logged)

c) Rubbing of Seals / Aluminium finger taps.

(Rubbing of Seals do take place in cold condition and the team

leader to ensure that such rubbings are normal / abnormal)

8.2.8 Trial run of APH for 2 Hrs each to be carried out with main motor
and stand by motor. Log readings to be made as mentioned in
8.2.6

8.2.9 Auto- start of stand by motor (Between main & standby motors) to
be electrically ensured.

8.3 Air Preheater (With Air Motor)

8.3.1 Ensure (Refer drawing enclosed)

g. Required air pressure (Around 5.0 KSC) at the supply

header to Air motor

h. Lubricator filled with oil.

i. Operation of solenoid valve

j. Pressure gauge in the Air supply line to Air motor.

8.3.2 Open the by pass valve manually and slowly operate air motor
vis--vis the APH

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 11 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
8.3.3 Operation of air motor vis--vis APH carried out for about 10
minutes. The same operation carried out by operating the
solenoid valve in the main line and APH operated for 10 minutes.

8.3.4 Interlock operation of APH running through Air motor checked by

creating the condition of electrical motors tripping (Main & Stand
by motors)

Note: Normally, the air motor is commissioned during erection of

APH to facilitate erection process.

8.4 APH Soot Blower

8.4.1 After ensuring the insulation value of the motor winding at

salisfactory level, the SB motor started and put on 4 Hrs trial run.
No load current logged once during the trial run.

8.4.2 Ensure

a. Coupling of motor with speed reducer

b. Coupling of Speed reducer & gear box
c. Erection completion of swivel link arrangement with gear
box and swivel arm.
d. Limit switches for sweep limit with its electrical
connections.
e. Recommended lubrication of speed reducer & gear box.
f. Cleanliness of the nozzles.
g. Air line connection to APH SB

8.4.3 Start the SB motor and observe for the entire operation of steam
nozzle movement from in board location to out board location and
back to in board location (Parking location). (Refer O & M manual
& enclosed drawing)

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 12 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

8.4.4 Set the limit switches for

a) Operating steam valve and

b) Stopping the SB at its parking location.

8.4.5 Charge the air line slowly and blow the SB arm and nozzle
sufficiently.

8.4.6 Ensure the operation of APH SB from remote along with steam
valve opening.

8.5 Flushing of Deluge & Water wash system

(Refer drawing enclosed)

8.5.1 Deluge and water wash system are similar in lay-out.

8.5.2 The line is charged up to system inlet isolating valve and flushed
sufficiently through its drain line to plant drain till clear water
observed at drain outlet.

8.5.3 Flushing the system into the APH to be carefully done after
ensuring proper draining facility at the bottom of APH (Through
APH hoppers. At no time, water allowed to get collected in APH
Hoppers)

8.5.4 Flushing through both deluge system and water wash system
carried out one by one sufficiently till clear water observed at
drain outlet.

8.5.5 After completion of flushing, deluge and water wash systems are
isolated and APH allowed for drying (Either by natural or by
running FD Fan and APH)

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 13 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS

8.6 General

8.6.1 Other miscellaneous system

a) Rotor stoppage alarm

b) Oil carry over unit

c) Light assembly for observation port

d) Interlocks with other systems of the boiler. All these

systems are commissioned separately through respective
sections in the O & M manual.

9.0 COMPLETION CRITERIA

Air Preheater commissioning (Both Primary and Secondary)

completed by carrying all the proposals given in section 3.0
(Section 3.1 to 3.6)

Signatures

NTPC BHEL
 SHEET 15 OF 16

10.0 LOG SHEET - I Date :

PROJECT :

UNIT NO.1 :

ACTIVITY : Lub-oil flushing (Guide Bearing / Support Bearing)

PUMP IN SERVICE DISCHARGE

Sl.No TIME REMARKS
A B PRESSURE

Signatures

NTPC BHEL
 SHEET 16 OF 16

10.0 LOG SHEET - II Date :

PROJECT :

UNIT NO. :

ACTIVITY : Trial run of APH Motor (No load) / APH.

MOTOR IN VIBRATION
Sl.
TIME SERVICE REMARKS
NO APH GEAR
MAIN/STANBY MOTOR
BOX

Signatures

NTPC BHEL
 TECHNICAL SPECIFICATION OF APH
SIMHADRI 2 X 500 MW

SL. NO DESCRIPTION PRIMARY APH SECONDARY APH

1. Type-Bisector 26.5 VI M 2000 30.0 VI 2000

2. Make BHEL BHEL

3. Total Heating Surface 33296 Sq.m 62720 Sq.m

4. Number of APH 2 Nos. 2 Nos

5. Motor Rating 11 KW 18.5 KW

PROCEDURE FOR COMMISSIONING OF APH
AND ITS AUXILARIES