1010Boiler Unit Startup Commissioning Procedure090320.docx
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1010Boiler Unit Startup Commissioning Procedure090320.docx
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1010BoilerUnitStartupCommissioningProcedure090320
CommissioningProcedureforBoilerUnitStartup
Page:
1of21
E07007
DocumentClass
1
CHENGDAENGINEERINGCORPORATIONOFCHINA
CHENGDAJOBNO.E07007
A
Forapproval
Nov.20,2008
ZhouZT
Rev.
Description
Date
Prepared
Checked
Reviewed
Approved
PT.PLN(PERSERO)
OWNER’S
DWG.NO.
PT.PLN(PERSERO)
JASASERTIFIKASI(LMK)
Client’sProjectNo.
PLTU2BANTEN-LABUAN(2x300MW)
Labuan,Banten,theRepublicofIndonesia
DWG.NO.
E07007-PR-TM-1010
ElectronicFileName:
DateofIssue:
RevisionNo.
Nov.20,2008
A
Thisdocumentisrestricted.NeitherhewholenoranypartofthisdocumentmaybedisclosedtoanythirdpartywithoutthepriorwrittenconsentofChengdaEngineeringCorporationofChina,inwhichthecopyrightofthisdocumentisvested.Allcopyrightsreserved.Neitherthewholenoranypartofthisdocumentmaybereproduced,storedinanyretrievalsystemortransmittedinanyformorbyanymeans(electronic,mechanical,reprographic,recordingorotherwise)withoutthepriorconsentofthecopyrightowner.
1.Purpose
Thereare3stagesinboilerunitstartupperiodthatarenoload,loadandfullload.Thepurposeofthisprocedureistoprovidethecommissioningprocedureforboilerunitstartup,ensurethatboilerunitcouldcompletetrialoperationandcansatisfynormalrunning.
2.Referencedocument
DrawingNO:
F289S-J0201B-02(03、04、16、17、18)
3.Instrument
DCSandLocalmetersforparameters.
4.Safetyprecautions
(1)Ifsomethingendangeringthesafetyofpeopleorequipmenthappenincommissioningperiod,correlativetestsmustbestopped,andifnecessarytheunitshouldbestoppedoperating.
(2)Testmustbestoppedifdangerousoccurredtobodyandequipmentduringtrialoperation,whichshouldbestoppedifnecessary
(3)Intensifyinspectionbeforestartupandeliminatedefectsofequipmentduringcoldconditiontest.Boilerunitstartupshouldcomplywithcurvesoftemperature,pressureandloadasspecificationandmoveasslowlyaspossible.
(4)Checkexpansionpositionofboilerwhenboilerstartupandhaltifexpansionbadness.
(5)InordertoprotectRHsafety,gastemperatureoutoffurnaceshouldbecontrolledbelow540℃asthereisnosteamflowtoRHafterboilerfired.
(6)AvoidmainsteamandRHsteamfromfluctuatingandwatercarryoverwhenturbinestartup.
(7)Payattentiontoequipmentautomaticstartandstopduringboilerunitstartup.
(8)CheckgastemperatureoutofAHandavoidsecondarycombustion.Sootblowingmustbeputintoserviceatoncewhentemperatureisabnormal.IntensifyAHsootblowingeverytwohoursearlyofboilerstartup
(9)Intensifycheckoffurnacepressurechangeandcombustioncondition,speciallyignitorsandmillstartupandstop.Adjusttokeepcombustionstabilization.
(10)Keepexhaustgastemperatureandfluegasoxygenconcentrationinspecifiedrangeandcontrolfluegasoxygenconcentrationat4%~5%.
(11)Checkauto-loopsoffurnacenegativepressure,secondaryairpressure,mainsteampressure,waterlevel,mainsteamtemperatureandRHsteamtemperature.
(12)CheckflamedetectorandfurnaceflameTVnormalandadjustcombustionatanymoment.
(13)Checkfurnacefluegastemperatureprobeandsoot-blowertoidentifytheyboostandquitatrightplace.
(14)CheckwalltemperatureofSHandRHwhenstartupandoperationtopreventpipesfrombreakdown.
(15)Intensifycombustionadjustmentandputoiltosupportcombustionwhenloadis60%MCRbeloworcombustionunstable.
(16)Fueloilsystemisstandbyduringboilerunitoperation.Oilgunmustberemovedfromfurnacewhenstop.
(17)Chooseappropriatecoalfineness.Gastemperatureoutofmillshouldbebelow75℃
(18)Payattentiontosteamtemperatureandpressure,load,surfacetemperatureandfluegastemperaturechangesaftercoalthrowing,andavoidtemperatureexcess.
(19)Atthebeginningofcoalthrowing,slagremovingshouldbeonetimeeachshift.
(20)Checkbearingtemperature,lubelevel,coolingwater,etc.ofrotaryequipment.
(21)Facilitiesshouldbecheckedregularlyandnomorethantwiceeachshift.
(22)Intensifysecuritywhentrialoperation.
(23)Ifthereissomethingnotmentionedinthisscheme,performaccordingtooperationregulationandaccidentdisposalregulation.
5.Necessaryconditionsforboilerunitstartup
Thereisturnoverpackagefromconstructionteamtocommissioningteamsaidthatsystemreadytotest.
5.1Sitecondition
(1)Siteisevenandtrafficissmooth,civilwokshasbeenfinishedandthereiscrawlandalarmsignatdangerousplace.
(2)Platformisremovedandsiteisclean.
(3)Ladderandrailareinstalled.
(4)Firefightingsystemisok.
(5)Drainagesystemcanbeputintoserviceandcoverboardsofditchesareallready.
(6)Watersupplyisready.
(7)Lightingisenough.
(8)Equipment,pipeandvalvearenamedwithsymbolhanged.
(9)Communicationsystemisready.
(10)Pipesarepaintedandaccepted.
(11)Airconditionandaerationfacilityareready.
(12)Elevatorisinservice.
(13)Fuelsystemandcoaltransfersystemhavebeenputintoservice.
(14)Coalbunker,ashhopperandboilerinnerareclean.
5.2Subsystemcondition
5.2.1Defectsremoved
Gasandairsystemhasbeenputintoserviceduringboilersteamblowingperiod,whoseDefectshavebeenremoved.
5.2.2Waterandsteamsystem
(1)Temporarypipeshavebeenresumed.
(2)HydraulicpressurepinsofsafetyvalvesofmainpipeandRHpipehavebeenremoved.
(3)Defectsofdrainagesystem,blowdownsystemandairdischargesystemhavebeenremoved.
(4)Expansionindicatorsareallready.
5.2.3Coalpulverizingsystem(noputintoserviceduringsteamblowingperiod)
(1)Millhasbeeninstalledwithmotorrunandstaticcheckcompleted.
(2)IndividualcommissioningofCoalfeederhasbeencompletedwithbeltbalanceverified.
5.2.4Fueloilsystem
(1)Defectsduringsteamblowingperiodhavebeenremoved.
(2)Flamedetectorofoilisready.
(3)Boostandquittestofoilgun.
(4)Logicfunctioncheckofoilgun.
5.2.5Coaltransfersystem
Individualoperationofcoaltransfersystemhasbeencompletedwhichissatisfiedwithcoalfeed.Differentcoalshouldbepartedincoalstorage.
5.2.6Ashhandlingsystem
Ashhandlingsystemcanbeputintoservice.
5.2.7Slaghandlingsystem
Slaghandlingsystemcanbeputintoservice.
5.2.8Sootblowingsystem
Staticactionofsootblowerisnormalandsootblowinglogicfunctioniseligible.
5.2.9Chemicaldosingandsamplingsystem
Chemicaldosingandsamplingsystem,periodicblowdownandcontinuousblowdownsystem,drainagesystem,airdischargesystem,anti-flushsystemandfillingnitrogensystemhaveallbeeninstalled.
5.2.10Auxiliaryequipmentlogic
SCSandFSSScheckhavebeenfinished.
5.2.11FlamedetectorandflameTVcanbeputintoservice.
5.2.12Gastemperatureprobe
Furnacegastemperatureprobehasbeentestedandadjustedwithflexibleandcredibleoperation.
5.2.13BTGtest
BTGtestofunithavebeencompletedandeligiblewithcorrectaction.
5.3Othercondition
(1)Chemicalmakingupwatersystemcansupplyeligibledemineralizedwater.
(2)Compressedairsystemcansupplyeligiblecompressedair.
(3)Housesupplysystemiseligible.
(4)Lightingandcommunicationsystemisready.
(5)Centerair-conditioningisready.
(6)Safetyelectricalsourcecanbeputintoservice.
(7)Circulatingcoolingwatercanbeputintoservice.
(8)Closedtypecoolingwaterofauxiliaryequipmentcanbeputintoservice.
6.TrialOperation
6.1Necessarypreconditioncheck
(1)Checksteam-watervalveswitchofdrumwaterlevelgaugeflexible.Keepwaterlevelclear.TVmonitorincentrecontrolroomandwaterlevelgaugecouldindicatedrumwaterlevelcorrectlyandcredibly.
(2)Checkfurnaceflamemonitoringsystem,flamesceneiscleanandcoolingairvalveisopened.
(3)C&Iinstrumentareverifiedandcanbeputintoservice.
(4)Expansionisfineandnoblockwhenexpanding.Expansionindicatorisfixedfirmlyandadjustedtozeropositionatcoldstate.
(5)Checkfastenconditionoftubes,supportsandhangers,thefixedpinofspringhangersshouldberemoved.
(6)Checksootblowerandpipesintegrity,sootblowercanboostandquitcorrectly.
(7)Therearenosundriesinboiler.Manholeandobservationholeareallclosed.
(8)Actionofexplosiondoorofboilerandcoalpulverizingsystemiscorrectandcredible.
(9)Preliminaryoperationofrotaryequipmentiscompletedwithinterlockandprotectioncredible.
(10)Checkfourcornersactionofregulatingmechanismofpendularburnerflexibleandcredibleinsynchronal.
(11)Checkregulatingmechanismofoilgunandignitorcorrectandcredible.
(12)Checkpipevalvesoffueloilsystemflexibleandoilpressuregaugefine.
(13)Checkdampersofgasandairsystemandcoalpulverizingsystemwhichareensuredintherightdirection
(14)SignalofDASisnormalandeachindicatorcanbeputintoservice.
(15)CheckcomputersworkswellandCRTdisplaymatchrealstate.
(16)Thereisenoughoilwithnormallevelandgoodwatercoolingforbearingandmotorofrotaryequipment.
(17)Valvesofvaporsystemareflexiblewithrightposition.
(18)Chemicaldosingsystemisintegritywithdosingdoorflexible.
(19)Wateriseligible.
Refertoappendix.
6.2Testbeforeboilerunitstartup
CarryoutBTGinterlocktestbeforeboilerunitstartupaccordingtopreceptandcheckMFTwithitsinterlockaction.
6.3Trialoperationprocess
Boilercold,warmandhotstatestart-upcurvesrefertoappendix.
6.3.1Noloadperiod
(1)Boilerwaterfeed
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