Indiabulls

Indiabulls

COMMISSIONING PROCEDURE
AIR PRE HEATER
NASHIK POWER PROJECT

INDIABULLS POWER LTD.

5 X 270 MW

COMMISSIONING PROCEDURE S No. 1 2 3 4 5 6 7 8 9 10 PLANT DETAIL OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PRECAUTIONS LIST OF CONTENT

AIR PREHEATER

EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES

a)

LOG SHEET

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COMMISSIONING PROCEDURE

AIR PREHEATER

S No. 1

STATUS PLANT DETAIL

Rotary Air Preheaters supplied are of Tri-Sector type and Separate APH (2 Nos.in each circuit) are given for Primary & Secondary Air Circuits. Rotary Air- Preheater generally comprises the following.
1.1 1.2 1.3 1.4

A.C Driven Motor 1 No Air Motor 1 No. (with connected pipings & fittings) Drive Gear Box. Rotating elements with support and guide bearing arrangement with forced lubrication system. Soot blower system. Fire Sensing device. Deluge system Water wash system Observation ports and light arrangement Rotor stoppage alarm Plant item completion list for Mechanical, Electrical and C & I are to be prepared at site. Oil carry over probe.

1.5 1.6 1.7 1.8 1.9 1.10 1.11

1.12

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AIR PREHEATER

1.12

For the following system, refer drawings mentioned. a) b) c) d) e) Guide Bearing Lub-oil System Support Bearing Lub-oil system SB swivel arm sweep Deluge system Water wash system f) Air Supply to Air Motor

OBJECTIVE To commission the rotary air Preheater and make it available for commissioning and operation of the main plant.

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. Trial Run of Main Drive Motor for 8 Hrs. Trial run of APH through main motor for 4 Hrs. Commissioning of Air Motor and APH operation for 10 minutes through Air Motor. Commissioning of rotation of rotor. Commissioning of soot Boiler system Flushing of Deluge and Water wash system.

3.2 3.3 3.4

3.5 3.6

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AIR PREHEATER

4 4.1

SERVICES REQUIRED Availability of manpower with required Tools for attending to any leak, cleaning of filters. Availability of operating personnel to co-ordinate the activities. Availability of lighting arrangements and communication in the operating floors. Availability of portable fire fighting equipments near test area. Availability of service water Availability of L.T supply Availability of Equipment cooling water. Availability of sufficient quantity of lub oil. Availability of plant air. Availability of steam for soot blowing. SAFETY PRECAUTIONS Debris in and around APH shall be removed Approach / stair case / platform wherever required are made available. Manhole doors kept open for inspection should be clearly guarded from any unauthorized persons entering in to APH. (Test team leader to ensure this) First aid test available near test area. Operation of local start / stop PB is ensured for perfect operation to facilitate stopping of APH in case of necessity.

4.2 4.3

4.4 4.5 4.6 4.7 4.8 4.9 4.10 5 5.1 5.2

5.3

5.4 5.5

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COMMISSIONING PROCEDURE 6 6.1

AIR PREHEATER

EMERGENCY PROCEDUES The test team should be aware of the procedure to be adopted in case of damage to machinery or injury to any personnel connected to the activity. The test team should be well aware of procedures to be adopted in case any abnormality in the activity. STATE OF THE PLANT APH and its associated system are erected as per recommended drawing. Acid cleaning of support and guide bearing Lub-oil line completed. All local instrumentation of Lub-oil system completed. Power supply systems for the pumps are commissioned and available for operation. Plant Air is available upto APH. Cooling water for support and guide bearing lub oil system is available for operation. (Equipment Cooling water System) Required local / remote C & I inputs for APH are made available. (List to be mutually prepared at site). Deluge and water wash lines are erected upto APH and drainage facility is ensured. APH fire sensing thermocouples are commissioned and kept ready for operation. 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. Oil in support and Guide bearings and fluid coupling are filled up with recommended oil up to correct level. (Refer O & M Manual).

6.2

7 7.1

7.2

7.3 7.4

7.5 7.6

7.7

7.8

7.9

7.10

7.11

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AIR PREHEATER

7.12

All erection log sheets are filled and signed by concerned agencies Flue gas ducts and Air ducts 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. Dampers at inlet and outlet of APH (flue gas) are made free and connected to its drive. All loose materials / debris lying on the dampers are cleared. Main motor (AC-1 No) is kept decoupled from fluid coupling. Service air line connection to Air Motor is complete with lubricator cum Regulator. Filters in the lub-oil system cleaned and put in position. Oil level in the main gear drive ensured up to its normal level. Local instrumentation of the gear drive completed. Insulation of APH should be completed in all respect before boiler light up with special attention given to Guide bearing area. Platforms, Ladders and other structures around APH are inspected and thermal expansion of APH casing in all direction ensured. Aluminum finger tabs sets installed after seals are set to the specification. Air Seal cover and water shield of support bearing and air seal cover of guide bearing are erected as per drawing. Hot end tracking arrangements are mounted properly and the system is free to move. Breathers of bearing are checked for clean condition.

7.13

7.14

7.15 7.16

7.17 7.18

7.19

7.20

7.21

7.22

7.23

7.24

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7.25 7.26

Light assembly and observation ports are in position and wired. Adjuster nuts of sector plates are fully tightened and locked to specification Lock nuts of axial seal plate adjusters are fully tightened. Entire APH plant inspected and ensured that all loose material are removed and all personnel are away from rotating equipment. All manhole doors are closed except one or two as decided by the test team leader. Oil carry over probe with cooling arrangement erected. Air preheater standstill alarm system is made ready. Air receiver tank is ready and filled with air. METHOD All related standard check list are duly filled. Ensure all P&I checks are complete and are kept in service. Acid cleaning and Oil Flushing of lub-oil system of support and Guide Bearing system. After completing the erection of the lub -oil system, oil lines are dismantled and acid cleaned following the steps given in the procedure. 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. After completion of motor trial run, both pump and motor are coupled.

7.27 7.28

7.29

7.30 7.31 7.32 8 8.1 8.2 8.3

8.3.1

8.3.2

8.3.3

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AIR PREHEATER

8.3.4

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 bearing, the bearing itself is the oil reservoir and oil circulated back to Bearings through filler and cooler) Leaks attended if noticed during oil circulation. Initially, the filters in the System are closely observed in terms of 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. Continue oil flushing till the pump discharge pressures stabilizes for a period of 4-6 Hrs

8.3.5

8.3.6

After completing the oil flushing, the filters are cleaned again and put back in to the system. Relief valve in the pump (or mounted in the discharge line) are set at 2.0 KSC above the normal operating pressure of the luboil system. For safety reasons, the oil flushing activity to be performed during day time. Air pre Heater (A.C. Motor) 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. After completion of motor trial run, motors are coupled to APH main gear drive through fluid coupling. Start the lub oil system of guide and support bearing assembly and establish circulation.

8.3.7

8.3.8

8.4 8.4.1

8.4.2

8.4.3

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8.4.4

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. Start the main motor again and allow APH to continuously run. Observe of a) Load current (To be logged) b) Vibration of motor and gear unit (To be logged)

8.4.5 8.4.6

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)

8.4.7

Trial run of APH for 2 Hrs to be carried out with AC motor. Log readings to be made. Auto- start to be electrically ensured. Air Preheater (With Air Motor) Ensure: a) Required air pressure (Around 5.0 KSC) at the supply header to Air motor b) Lubricator filled with oil. c) Operation of solenoid valve d) Pressure gauge in the Air supply line to Air motor. Open the bypass valve manually and slowly operate air motor vis--vis the APH 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.

8.4.8 8.5 8.5.1

8.5.2

8.5.3

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8.5.4

Interlock operation of APH running through Air motor checked by creating the condition of electrical motor tripping. Note: Normally, the air motor is commissioned during erection of APH to facilitate erection process.

8.5.5 8.6 8.6.1

Rotate APH with manual handle. APH Soot Blower After ensuring the insulation value of the motor winding at satisfactory level, the SB motor started and put on 4 Hrs trial run. No load current logged once during the trial run. Ensure: a) b) c) d) e) Coupling of motor with speed reducer Coupling of Speed reducer & gear box Erection completion of swivel link arrangement with gear box and swivel arm. Limit switches for sweep limit with its electrical connections. f) Recommended lubrication of speed reducer & gear box. g) Cleanliness of the nozzles. h) Air line connection to APH SB

8.6.2

8.6.3

8.6.4

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. Set the limit switches for: a) Operating steam valve and b) Stopping the SB at its parking location.

8.6.5

Charge the air line slowly and blow the SB arm and nozzle sufficiently. Ensure the operation of APH SB from remote along with steam valve opening.

8.6.6

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8.7 8.7.1 8.7.2

Flushing of Deluge & Water wash system Deluge and water wash system are similar in lay-out. 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. 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) Flushing through both deluge system and water wash system carried out one by one sufficiently till clear water observed at drain outlet. 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) General Other miscellaneous system: a) Rotor stoppage alarm b) Oil carry over unit c) Manual rotating of the rotor. d) Light assembly for observation port e) Interlocks with other systems of the boiler. All these systems are commissioned separately through respective sections in the O & M manual.

8.7.3

8.7.4

8.7.5

8.8 8.8.1

9 9.1

COMPLETION CRITERIA Air Preheater commissioning completed by carrying all the proposals given in section 3.0 (Section 3.1 to 3.6)

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AIR PREHEATER

LOG SHEET - I PROJECT : UNIT NO. : ACTIVITY:

S No. TIME A

INDIABULLS REALTEC LTD.

Lub-oil flushing (Guide Bearing / Support Bearing)

PUMP IN SERVICE B DISCHARGE PRESSURE REMARKS

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COMMISSIONING PROCEDURE

AIR PREHEATER

LOG SHEET - II PROJECT : UNIT NO. : ACTIVITY:

S No. TIME

INDIABULLS REALTEC LTD.

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

MOTOR IN SERVICE MAIN / STAND BY VIBRATION MOTOR APH GEAR BOX REMARKS

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