Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 1 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES SLNO LIST OF CONTENTS 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 STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES a) DRAWINGS b) LOG SHEET

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 2 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 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 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 A.C Driven Motor 2 No Air Motor 1 No 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.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 3 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 1.12 For the following system, drawings are enclosed in Section 10.0 a. b. c. d. e. f. 2.0 Guide Bearing Lub-oil System Support Bearing Lub-oil system SB swivel arm sweep Deluge system Water wash system Air Supply to Air Motor

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 3.2 3.3 3.4 Signatures

Acid cleaning & oil flushing of Lub-oil system of support & Guide bearings. Trial Run of Main Drive Motors 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.

NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 4 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 3.5 3.6 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5.0 5.1 5.2 5.3 Commissioning of soot Boiler system Flushing of Deluge and Water wash system. 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 service water Availability of L.T supply Availability of Equipment cooling water. SAFETY PRECAUTIONS: Debris in and around APH shall be removed Approach / stair case / platform wherever required are made available. 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 NTPC Ref no SIM/1/TS/1/36

Sheet 5 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 5.4 5.5 6.0 6.1 First aid test available near test area. Operation of local start / stop PB are ensured for perfect operation to facilitate stopping of APH in case of necessity. EMERGENCY PROCEDUES: 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. 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. No. PS-DC-186-500-0013A) All local instrumentation of Lub-oil system completed. Power supply system for the pumps are commissioned and available for operation. Instrument and service Air is available upto APH. Cooling water for support and guide bearing lub oil pumps is available for operation. (Equipment Cooling water System) Required local / remote I & C inputs for APH are made available. (List to be mutually prepared at site). NTPC BHEL

6.2 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 Signatures

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 6 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 7.8 7.9 7.10 Deluge and water wash lines are erected upto APH and drainage facility is ensured. APH fire sensing device 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). All erection log sheets are filled and signed by concerned agencies 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. 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. Main motors (AC-2 Nos) are kept decoupled from fluid coupling. Service air line connection to Air Motor is complete with lubricator cum Regulator. Fillers in the lub-oil system cleaned and put in position.

7.11 7.12 7.13

7.14

7.15 7.16 7.17

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 7 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 7.18 7.19 7.20 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. Aluminium 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. 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 man hole doors are closed except one or two as decided by the test team leader.

7.21 7.22 7.23 7.24 7.25 7.26 7.27 7.28 7.29 Signatures

NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 8 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 8.0 8.1 8.1.1 METHOD: 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 No. PS-DC-186-500-0013A. 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. 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. 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. Continue oil flushing till the pump discharge pressures stabilises for a period of 4-6 Hrs.

8.1.2

8.1.3 8.1.4

8.1.5

8.1.6 Signatures

NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 9 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 8.1.7 8.1.8 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 lub-oil system. For safety reasons, the oil flushing activity to be performed during day time. Air pre Heater (With Main & stand by 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 . Step 8.2.1 to be repeated for both main and standby motor of APH gear drive assembly. 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. 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 continonsly run.

8.1.9 8.2 8.2.1

8.2.2 8.2.3 8.2.4 8.2.5

8.2.6 Signatures

NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 10 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 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 Auto- start of stand by motor (Between main & standby motors) to be electrically ensured. Air Preheater (With Air Motor) Ensure (Refer drawing enclosed) g. h. i. j. 8.3.2 Signatures NTPC BHEL Required air pressure (Around 5.0 KSC) at the supply header to Air motor Lubricator filled with oil. Operation of solenoid valve Pressure gauge in the Air supply line to Air motor.

8.2.9 8.3 8.3.1

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

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 11 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 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 8.4.1 APH Soot Blower 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. Ensure a. b. c. d. e. f. g. 8.4.3 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. Recommended lubrication of speed reducer & gear box. Cleanliness of the nozzles. Air line connection to APH SB

8.4.2

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 NTPC Ref no SIM/1/TS/1/36

Sheet 12 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 8.4.4 Set the limit switches for a) Operating steam valve and b) Stopping the SB at its parking location. 8.4.5 8.4.6 8.5 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. Flushing of Deluge & Water wash system (Refer drawing enclosed) 8.5.1 8.5.2 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)

8.5.3

8.5.4

8.5.5

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0036 NTPC Ref no SIM/1/TS/1/36

Sheet 13 of 16

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES STATUS SL.NO 8.6 8.6.1 General 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)

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SHEET 15 OF 16 10.0 PROJECT UNIT NO.1 ACTIVITY : : : Lub-oil flushing (Guide Bearing / Support Bearing) LOG SHEET - I Date :

Sl.No

TIME

PUMP IN SERVICE A B

DISCHARGE PRESSURE

REMARKS

Signatures NTPC BHEL

SHEET 16 OF 16 10.0 PROJECT UNIT NO. ACTIVITY : : : Trial run of APH Motor (No load) / APH. LOG SHEET - II Date :

Sl. NO

TIME

MOTOR IN SERVICE MAIN/STANBY

VIBRATION MOTOR APH GEAR BOX REMARKS

Signatures NTPC BHEL

TECHNICAL SPECIFICATION OF APH SIMHADRI 2 X 500 MW

SL. NO 1. 2. 3. 4. 5.

DESCRIPTION Type-Bisector Make Total Heating Surface Number of APH Motor Rating

PRIMARY APH 26.5 VI M 2000 BHEL 33296 Sq.m 2 Nos. 11 KW

SECONDARY APH 30.0 VI 2000 BHEL 62720 Sq.m 2 Nos 18.5 KW

PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES