AUX BLR FAN

7/28/2019 AUX BLR FAN

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Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0032

NTPC Ref no SIM/1/TS/2/32Sheet 1 of 9

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)

SLNO

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

PLANT DETAILS

OBJECTIVE

PROPOSAL

SERVICES REQUIRED

SAFETY PERECAUTIONS

EMERGENCY PROCEDURE

STAE OF THE PLANT

TEST METHOD

COMPLETION CRITERIA

APPENDICES

a. LOG SHEET


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Plant area: BOILER


SLNO

1.0

2.0

3.0

4.0

5.0

6.0

PLANT DETAIL:

Refer to procedure for commissioning of Auxiliary Boiler.

OBJECTIVE:

To commission a) Forced Draft Fan andb) Boiler Feed Pump of auxiliary Boiler.

PROPOSALS:

It is proposed to commission the auxiliaries by conducting trialrun for 8 Hrs at low load condition.

SERVICES REQUIRED:

Availability of L.T Power supply.

Availability of lighting, communication facility around theauxiliaries area.

Availability of sufficient quantity of DM water.

Availability of Service and Instrument air

Availability of cooling water.

SAFETY PRECAUTIONS:

Refer Procedure No.PS-DC-186-500-100/SIM/1/TS/2/100

EMERGENCY PREPARDNESS:

Refer Procedure No.PS-DC-186-500-100/SIM/1/TS/2/100

STATUS

Signatures

NTPC BHEL


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Plant area: BOILER



4/20

SLNO

7.0

7.1

7.1.1

7.1.2

7.1.3

7.1.4

7.1.5

7.1.6

7.1.7

7.1.8

7.1.9

STATE OF THE PLANT:

FORCED DRAFT FAN

Erection of Fan and Motor completed as per recommendeddrawing and check lists.

Erection of the auxiliary boiler completed including ducts from fandischarge up to chimney completed.

All permanent supports are erected as per drawing for bothpressure parts & non-pressure part.

Suction cum Requlating damper and discharge dampers are

erected and are freely operating.

Fan bearings are lubricated as per recommended lubricationschedule.

All debris and temporary supports inside the fumace and ductsare removed.

Electrical connection to FD Fan Motor is completed withrecommended protections and the required mock start / stopconducted satisfactorily under Fan and Motor in decoupled

condition.

Insulation Resistance of the motor measured and confirmed OK.

All local and remote instrumentation of the Fan are made ready(List of Indication, Interlock & protection required made mutuallyby BHEL & NTPC)

STATUS

Signatures

NTPC BHEL


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Plant area: BOILER


SLNO

7.2

7.2.1

7.2.2

7.2.3

7.2.4

7.2.5

7.2.6

7.2.7

7.2.8

7.2.9

BOILER FEED PUMP:

Erection of Pump and Motor completed as per recommendeddrawing and checklist.

Erection of Feed water system from Deaerator Feed storagetank, Suction pipe line, discharge pipe line up to Boilercompleted.

All permanent supports of the Feed Water System are erected asper drawing.

Pump bearings are lubricated as per recommended lubricationschedule.

Feed storage tank is cleared off debris.

Electrical connections to BFP Motor is completed withrecommended protections and the required mock start / stopconducted salisjactorily under pump and motor in decompled

condition.

Insulation Resistance of the motor measured and confirmed OK.

All local and remote instrumentation of the pump are made ready.(List of indications, interlocks and protection required mademutually by BHEL and NTPC).

CW lines are connected to pump (If applicable)

STATUS

Signatures

NTPC BHEL


6/20



Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)SLNO

8.0

8.1

8.1.1

8.1.2

8.1.3

8.1.4

8.1.5

8.2

8.2.1

8.2.2

8.2.3

METHOD:

A) FD FAN:

Under decompleted condition, start the motor and checkdirection of rotation.

Motor started and 8 Hrs trial run completed. During the trial run,

observation made for normal vibration and bearing temperatures.

Fan and Motor are compled and Air & flue gas ducts are lined upfor fan running.

Fan started keeping the suction cum regulating damper inminimum and discharge damper in closed condition.

Loading of the fan gradually raised to around 20-30% and 8 Hrstrial run carried out. During the trial run, Fan Vibration, loadcurrent, bearing temperatures and furnace pressure are logged.

B) BFP:

Under decoupled condition, start the motor and check direction ofrotation.

Motor started and 8 Hrs trial run completed. During the trial run,observations are made for normal vibration and bearingtemperatures.

Pump and motor coupled and Feed water system from Deaerator

Feed storage Tank to pump ready with RC line open anddischarge valve closed.

STATUS

Signatures

NTPC BHEL


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Plant area: BOILER


8.2.4

8.2.5

Pump started and put for 8 Hrs trial run through re-circulation line.

During the trial run, pump vibration, local current, bearingtemperatures, suction and discharge pressures are logged.

STATUS

Signatures

NTPC BHEL


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Plant area: BOILER


9.0

9.1

9.2

COMPLETION CRITERIA:

FD Fan run for 8 Hrs trial run satisfactorily.

BFP run for 8 Hrs trial run satisfactorily.

STATUS

Signatures

NTPC BHEL


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SHEET 8 OF 9

10.0 LOG SHEET

DATE:

STATION :UNIT NO :ACTIVITY : TRIAL RUN OF FD FAN

S.NO.FAN LOADING DISCHARGE

PRESSUREFUMACE

PRESSURE

BEARINGTEMPERATOR

IGV AMPS DE NDE

Signatures

NTPC BHEL


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SHEET 9 OF 9

10.0 LOG SHEET

DATE:

STATION :UNIT NO :ACTIVITY : TRIAL RUN OF BFP

S.NOPUMP

LOADING

AMPS

PRESSUREBEARING

TEMPERATURE

SUCTION DISCHARGE DE NDE

Signatures

NTPC BHEL


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PROCEDURE FOR COMMISSIONING OF

AUXILIARY BOILER (FD FAN & BFP)


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Plant area: OFF SITE

PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM

SLNO

1.0 PLANT DETAILS:

Oil Handling System forms a part of fuel oil plant. Refer totesting schedule No.PS-DC-186-500-0008/(SIM/1/TS/1/007)

The plant details of the oil handling system is given in section 1.0of above referred testing schedule.

Technical Specifications of Drain oil System

Drain oil System

No. of Pumps : 1Capacity : 10 Cu.M./HrType : Vertical, Single Screw.Tank : 10 Cu.M

Oil Water Separator System

No.of Pumps : 2 Nos, of Oil Recovery Pumpsand 2 Nos.of Sump Pumps.Capacity : 10 Cu.M/Hr for ORP & 30 Cu.M / Hr

For Sump Pump.

STATUS

Signatures

NTPC BHEL


13/20


NTPC Ref no SIM/0/TS/4/152Sheet 2 0f 7



SLNO

2.0

3.0

3.1

3.1.1

3.1.2

3.13

3.1.4

3.1.5

3.2

OBJECTIVE

To clean and commission the LFO & HFO handling systemincluding the pressurizing pumps and make it available for mainunit commissioning and operation .

PROPOSAL

Following proposals will be followed to achieve the objective

Cleaning of LFO Handling system.This is further divided into

LFO Receiving Terminal (Cleaning by Compressed air at 4-5KSC)

Piping from LFO terminal to suction of LFO Handling Pump.

LFO Handling Pump discharge to inlet points of LFO Day tankand LFO storage tank.

Sl.No.3.13 and 3.14 are cleaned by card board bursting methodas described in section 8.0

Cleaning of HFO handling SystemRefer to Testing Schedule PS-DC-186-500-0008 /(SIM /1/ TS/1/007)

STATUS

Signatures


14/20

NTPC BHEL




PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEMSLNO

3.3

4.0

5.0

6.0

7.0

7.1

Commissioning of all pumpsa) Unloading Pumps of LFO / HFO

System Trial run for 2 Hrsb) Pressurizing Pumps of LFO / HFO

System Trial run for 8 Hrsc) Pumps of Drain Oil System

Trial Run for 1 / Hrs (By local recirculation)

SERVICES REQUIRED

SAFETY PRECAUTIONS

EMERGENCY PRECAUTIONSFor Sections 4.0, 5.0 & 6.0, refer to the corresponding sectionsof the following procedures.

a) PS-DC-186-500-151 / (SIM / 1 / TS / 4 / 151)

b) PS-DC- 186- 500 - 0008 / (SIM / 1 /TS / 1 / 007)

STATE OF THE PLANT

Hydraulic Test, Support work and Insulation of the following linesare completed.

1. LFO / HFO unloading heoder2. Line from LFO / HFO unloading heoder to LFO / HFO

unloading Pumps3. Line from LFO / HFO unloading pumps to LFO / HFO

storage and

Day Tanks.4. LFO / HFO Storage and Day Tanks to LFO / HFOpressurizing pumps and their respective RC lines

5. Drain oil and oil water Separator system.

STATUS

Signatures


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NTPC BHEL



Plant area: OFF SITEPROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM

SLNO

7.2

7.3

7.4

7.5

7.6

7.7

7.8

Erection of the following completed as per recommendeddrawing.

1. LFO /HFO unloading Pumps.

2. LFO / HFO pressurizing pumps.

3. Pumps of Drain oil and Oil water Seperator system

4. LFO / HFO storage and Day tanks.

Auxiliary Boiler is fully ready for supplying Steam

Trip valves, Control Valves are not erected and suitable spoolpieces are erected at these places

Filter elements and NRV internals removed.

Temporary exhaust pipe lines for steam blowing erectedwherever required, avoiding machinery and Buildings.

All vents and drains are properly routed and supported.

Local level indicators of LFO / HFO storage and Day tanks aremade available.

STATUS

Signatures


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NTPC BHEL




PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEMSLNO

7.9

7.10

7.11

7.12

8.0

8.1

8.1.1

8.1.2

8.1.3

8.2

8.2.1

Road and rail approach to the Oil handling area is complete tofacilitate LFO / HFO unloading.

All steam lines as well as HFO lines are insulated.

No permanent Instruments are erected in lines being steamblown. They are isolated incase erected.

All electrical systems required for pump commissioning are madeavailable.

METHOD

LFO Handling System.

LFO receiving Terminal is cleaned by compressed air blowing ata pressure of 4 5 kg / cm. Air admitted at a suitable inlet pointand blown one by one through other openings.

Sl.No.3.1.3 and 3.1.4 are cleaned by card board bursting methodby providing a card board at a suitable location and pressurizingthe line to 3 4 KSC. The card board bursts and effects cleaningof the pipe line.

Air inlet point and location for putting card board to be decided atsite.

HFO Handling system

Refer to Testing Schedule PS DC 186 500 0008(SIM / 1 / TS / 1 / 007)

STATUS

Signatures

NTPC BHEL


17/20

Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152NTPC Ref no SIM/0/TS/4/152

Sheet 06 0f 07




18/20

SLNO

8.3

8.3.1

8.3.2

8.3.3

8.4

8.4.1

8.4.2

8.4.3

8.4.4

8.4.5

8.4.6

STORAGE AND DAY TANKS

Hydraulic fill test of Storage and Day Tanks of LFO / HFO systemare completed as per suppliers recommandation.

After satisfactory hydraulic fill test, water drained and tanks areallowed for drying.

The tanks are manually cleaned thoroughly and manhole doorsboxed up before pumping LFO / HFO oil into the tanks.

COMMISSIONING OF PUMPS

Insulation value of the motor measured and ascertained that thevalves are satisfactory.

Motor bumped and ensured correct direction of rotation.

All the motors are trial run for 2 Hrs and during the trial run, motornoload current noted down.

After coupling the motor with pump, oil lines are slowly charged /vented / drained to the required amount and the pumps areprimed sufficiently.

Pump started and put on trial run under recirculation duration asgiven in section 3.3. During trial run, load current of the pumpnoted.

All the leaks observed during charging and filling up of unloadingterminal Header, oil lines, storage and day tanks are attendedexpediously.

STATUS

Signatures

NTPC BHEL






19/20

SLNO

9.0

10.0

COMPLETION CRITERIA

Cleaning and commissioning of LFO / HFO Handling system

including pressurizing pump completed by following the proposalsas given in section 3.0

a) Drawings referred are

i) PE DG 186 166 0001 ( P & ID for FO System)ii) PE DG 186 166 0003 ( P & ID for LDO System)

STATUS

Signatures

NTPC BHEL


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PROCEDURE FOR COMMISSIONING OF OILHANDLING SYSTEM

AUX BLR FAN

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