XXIV.

BOILER COMMISSIONING
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Contents
1. INTRODUCTION
2. PLANNING AND PREPARATIONS
3. INSPECTION AND PRECOMMISSIONING CHECKS
4. TRIAL RUN OF THE EQUIPMENTS
5. PRECOMMISSIONING ACTIVITIES
6. TRIAL OPERATION OF BOILER
7. PERFORMANCE TESTING
8. TRAINING OF OPERATING AND MAINTENANCE STAFF
FIG. XXIV-1 SCHEME OF CHEMICAL CLEANING (INFORMATIVE)
FIG. XXIV-2 STEAM BLOWING - PUFFING METHOD FOR
REHEAT BOILERS
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XXIV. BOILER COMMISSIONING
1. INTRODUCTION
The present trend in utility and industrial market is to go in for large capacity, high pressure
steam generators. These steam generators commonly known as boilers have a number of
auxiliaries and sophisticated controls. Their size and complexity render them unsuitable for
shop assembly and testing in most cases. Hence all the components of the steam generator
have to be assembled and tested only at site. The operation of checking the equipments and
tuning them before putting into commercial service is commonly termed as Commissioning.
Generally commissioning a steam generator aims at accomplishing the following objectives:
i) Preparation of the equipments for reliable and trouble-free operation.
This may involve:
a) Inspection, pre-operational checking and preparation of the epuipments including
specialised cleaning.
b) Trial run, initial operation and performance monitoring.
c) Problem analysis and solution.
ii) Fulfilling contractual obligations like proving performance guarantee.
iii) Compiling and creation of equipment performance data for future reference and
comparison.
iv) Training of operation and Maintenance personnel.
Frequently some of the equipments or subsystems of the boiler, like auxiliaries, coal handling
plant, ash handling plant, service equipments and electrical systems are engineered by different
agencies. For successful commissioning of the steam generator all these equipments should
be made ready at appropriate stages of boiler commissioning This involves effective
co-ordination, and is an aspect of project management in commissioning. While details of
this aspect of commissioning are not being covered in this chapter, mention will be made of
the -same at the relevant sections for the sake of completeness.
Broadly, the activities during commissioning of a boiler can be divided into seven stages
from preparation to performance testing of the unit:
i) Planning and preparations.
ii) Pre-commissioning inspection and checks.
iii) Trial run of equipments.
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iv) Pre-commissioning activities Including specialised cleaning.
v) Trial operation of boiler and setting parameters for operation regimes.
vi) Performance testing.
vii) Training of operation and Maintenance personnel.
2. PLANNING AND PREPARATIONS
Planning for commissioning the unit should start even during the early stage of contract. The
contract specification should be clear in scope of work and demarkation of responsibilities of
executing agencies.
To facilitate smooth commissioning, agreements should be reached on procedures for trial
runs, testing, activities like chemical cleaning, steam blowing and other commissioning
activities even in the contract stage. For effective utilisation of resources at site as also for
efficient monitoring a PERT chart or a bar chart of commissioning activities should be prepared.
This can be done after ascertaining the planned dates of activities and readiness of requisite
inputs like power, water, fuel, lubricants, service facilities and trained personnel. For more
realistic scheduling this is best done after a site inspection by an experienced commissioning
engineer.
The commissioning team, before setting up office at site will study the contract specification,
design calculations, anticipated, and guaranteed performance figures, various boiler schematics
and operation and maintenance instructions. The lead commissioning engineer will do the
planning for getting ready all commissioning documents like equipment check lists, trial run
instructions report format etc. He will also establish the site office and organise other site
requirements like manpower, instruments etc.
3. INSPECTION AND PRECOMMISSIONING CHECKS
The first important commissioning activity at site is the inspection and checking of equipments.
Generally this activity is meant to ensure erection completion, compliance of critical
dimensions, tolerances, removal of unwanted material and access facilities for maintenance
and inspection.
All the air and gas paths including ducts should be checked for completeness of work, correct
supporting, expansion provision where required and proper flanged and welded connections.
The complete system should be cleaned of all debris. Proper application of insulation to
minimise heat loss and to ensure human safety, should also be checked up.
3.1 Steam Drums
The steam drum should be checked for correct fit-up of internals and cleanliness, All safety
valve nozzles, water column nozzles, vent nozzle, pressure gauge nozzles, down corner nozzles
etc., should be checked for any obstruction. The drum should be free to expand in all the
required directions. The water level gauge and water level instrument connections should be
strictly installed as per drawings.
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3. 2 Superheater, Reheater, Desuperheater and Economiser
Cleanliness is one of the prime requirements in this area. The assemblies should be checked
for transverse and longitudinal spacings. Any misalignment should be corrected . Supports,
expansion clearances, correct installation of cooled and uncooled spacers, vibration snubbers,
gas baffles, etc., should be checked. The permanent and temporary thermocouples are to be
checked for correct location and installation. These should be identified and tagged. Heat
check should be done on each thermocouple to ensure continuity and response.
3.3 Waterwalls and Buckstays
All the waterwalls and other areas subjected to expansion movements should be checked up
for any tie up with structural steel. Adequate expansion clearances and guiding must be
provided. Correct location of openings like access doors, observation ports and instrument
tapping points should be checked. For measurement and verification of unrestrained thermal
expansion, indicators should be mounted at the required locations.
The buckstay system should be checked for correct installation and insulation filling wherever
envisaged. Corner connections and intersections between vertical and horizontal stays and
front and rear pass buckstays should be checked for proper arrangement. Generally the surface
guides also form part of the buckstay system. These should be checked for correctness of
location, sturdiness and marked up for indicating expansion movements.
The bottom ash hoppers may be checked for any possible spray or splashing of water on to the
waterwall tubes. Water seals also should be checked for expansion clearances and adequacy.
3.4 Hangers and Supports
All hangers of the boiler, headers, ducts and piping should be checked up for correct location
and loading. Spring compression in the case of spring type hangers, should be strictly as per
design. Both the spring and constant load hangers should have adequate expansion range. All
spring stops and locking devices should be brought to operating positions or removed and
accounted.
3.5 Safety Valves
Correct location of the safety valves should be ensured. The hydrostatic test plug to safety
valves must be removed prior to firing the unit. After hydrostatic testing all the valves should
be cleaned, assembled and made ready for setting.
The safety valve vent pipes should be properly supported with adequate expansion clearances
around the drip pan. Drains of adequate size must be provided as indicated in the 0 & M
instruction.
3.6 Tangential Wind Boxes
The wind box in general should be checked for proper installation as per drawing. The fuel
piping should have adequate and proper supports. The shouldnt load the coal nozzles. The
secondary air dampers must be free to open and close with adequate opening for cooling air at
fully closed position. Tilt should be operable through full range. The linkage connection for
tilting and wind box dampers should be checked witty respect to drawing. While tilting, all
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the nozzles in the same corner and at each elevation in different corners should tilt in unison
within the allowed variation. The internal clearances between wind box frame end nozzles
and burner panel should be as per design.The oil piping around the wind box should be
properly routed and supported. Flexible hoses must be connected without any twist or bending
and must allow for cubical expansion of the wind box and free travel of retract mechanism.
The location of the diffuser in the oil compartment and the tip position with respect to diffuser
is a critical dimension. This should be strictly within the tolerance specified.All the oil and
atomising air lines must be steam blown and the oil piping flushed sufficiently long enough
to ensure cleanliness.
The area around the wind boxes must be clean. Adequate clearance and handling provision
for removing oil guns and coal nozzles must be ensured.The ignitors and ignition system
including control cabinets should be critically examined for proper installation.
3.7 Rotating Equipments
The rotating equipments including fans, airheaters and pulverisers should be completely
checked as per the 0 & M manuals and manufacturers recommendations. Gaps and clearance
inside the mills airheaters and all bearings must be checked and adjusted. Correct direction
of rotation and proper allingnment with the drive also should be ensured. The correct
functioning of all the protective interlocks must be checked and recorded.
3.8 Instrument Tappings
All the instrument tappings and impulse lines must be checked for proper installation with
adequate facilities for cleaning and maintenance.
3.9 F.S.S.S.
Checking the F.S.S.S. system involves elaborate work of checking the field equipments, wiring
and simulation including testing various protections. As the F.S.S.S. is intended for ensuring
safe operation of the boiler checking should be meticulous and by passing of interlocks and
protections should be avoided.
4. TRIAL RUN OF THE EQUIPMENTS
All the rotating equipments must be individuality trian run. Normally before trial run of
equipments service, facilities like power, cooling water and lubricants must be made available.
Prior to trial run of the equipment, the drive unit (normally an electric motor) will be trial run
in the uncoupled condition. To start with pre-commissioning checks on the motor should be
completed and protection and interlocks tested. After successful completion of trial run of the
drive, the equipment will be coupled and trial run at no load, for about 8 hours. During the
trial run, equipments will be Carefully observed for any unusual noise, abnormal vibrations
or undue bearing temperature rise. Any defects noticed should be immediately attended and
the trial run repeated till satisfactory results are obtained.A record of the trial run including
the vibration readings, bearing temperature rise, starting current, no load current, time of
acceleration, deceleration, defects noticed and rectifications carried out should be maintained
for future reference.
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5. PRECOMMISSIONING ACTIVITIES
It is a general practice to carry out the following tests and activities before commencing
trial operation of the boiler:
i) Air and gas tightness tests.
ii) Chemical cleaning of the boiler.
iii) Thermal flow test.
iv) Steam blowing.
v) Safety valve setting.
vi) Clean air flow test of pulverisers.
vii) Testing of protection and interlocks.
viii) Calibration of instruments.
5.1 Air and Gas Tightness Tests
The air tightness and gas tightness tests are conducted to detect the source of leakages in the
system. This should be carried out before applying the insulation. Prior to carrying out this
test all the pre-commissioning checks of components in the system including dampers should
have been completed and the access doors, observation ports, and other openings closed and
secured properly.
For conducting gas tightness test following procedure is generally used - Run F.D. fan and
open all the dampers in air and flue gas path excluding I.D. fan discharge dampers. (I.D. fan
should not be run and the I.D. fan running interlock for F.D. fan running should be bypassed).
Pressurise the flue gas path to at least 50 mm of water column. The furnace pressure should
not exceed 100 mm of W.C. Light up a smoke bomb in the furnace and one in the second pass
through suitable openings, the opening should be closed. Check manhole doors, peephole
doors, duct joints, fan flanges, hopper joints etc., for leakage. The location of leakage points
may be marked and recorded for rectification. Repeat the test after rectification to ensure that
the system is tight in all respects.
Similar procedure is adopted for conducting air tightness test. This is done by running F.D.
fans and keeping all the dampers in air path open except for the dampers in the wind box. The
system is pressurised to 100 mm of water column. A smoke bomb is introduced and lighted
up in the suction of each fan.
5.2 Chemical Cleaning of the Boiler
The internal surfaces of a boiler in contact with water or steam must be kept clean for efficient
heat transfer, maintaining steam purity and to avoid pressure part failures. Most steam generator
manufacturers recommend chemical cleaning of the unit for this purposes. Cleaning process
adopted can be generally classified under alkali-boil out and acid cleaning.
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Alkali boil out is carried out to remove materials such as lubricants, oil and rust.
Acid cleaning of boilers removes scales and deposits formed on the heat transfer surfaces in
contact with water. This also removes mill-scales and corrosion products found in the steam
generator.
As a standard practice, the steam generating surface (i.e. water walls) only are chemically
cleaned. For low pressure industrial boilers alkali boil out alone may be adequate, while for
boilers with high operating pressure alkali boil out is followed by acid cleaning.
Chemical cleaning of the boiler should be preceded by cleaning of the pre-boiler system. This
is accomplished by hot alkaline mass flushing to remove loose debris and silica bearing
deposits.
5.2.1 Alkali Boil Out
As already stated the alkali boil out is carried out to remove water and alkali soluble and
saponifiable compounds from water side surfaces of the unit. Sand, loose Mill scale, and
corrosion products formed on the tube surfaces during erection and following hydraulic test
are also removed by blow-down during the boil out process.
Generally the alkaline chemicals used for boil out is a combination of one or more of the
following chemicals :
i) Caustic soda NaOH
ii) Soda ash Na
2
CO
3
iii) Tri sodium phosphate Na
2
PO
4
12H
2
O
iv) Sodium sulphite Na
2
SO
2
v) Sodium nitrate Na
2
NO
3
Of the above soda ash and tri sodium phosphate are the most commonly used chemicals.
Sodium sulphite is used to reduce oxygen corrosion and sodium nitrate is added to prevent
the possibility of Caustic embrittlement. In addition to those chemicals a detergent may also
be added.
The boil out process may be preceded by hot and cold water flushing of the System to remove
loose debris and sand. As this may be the first time the steam generator is fired, the firing
system, the draft system and the instrumentation must be ready. To facilitate checking up free
and uniform expansion of the unit while raising pressure, the firing rate should be maintained
at minimum level. For modern high pressure boilers with welded water walls and wall
superheaters, any refractory drying will also be carried out during this process itself.
Preparatory to boil out, the boiler should be filled with water to the normal operating level in
steam drum. The chemicals may be added through the normal chemical feeding system in the
drum or introduced into the steam drum through an open manhole.
Steam pressure is then raised slowly by firing the ignitors and warm up guns. To ensure
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adequate circulation of water and good mixing of chemicals in natural circulation boilers, the
pressure is raised to about 1/5 the normal operating pressure or 25 kg/Cm
2
(G) whichever is
lower. Low pressure units may be boiled out at pressures above 7 kg/cm
2
(G). The pressure is
maintained at this level till satisfactory results are obtained. Every 2 to 4 hrs. low point drains
in the ring header are opened for blow down for about 2 minutes after putting out the fire.
During the process alkalinity, silica level, pH and oil content are monitored at frequent intervals.
Samples may be taken from the continuous blow-down line and ring header drain. The process
is terminated when the oil content reduces to satisfactory level (generally less than 1 P.P.M.).
At the completion of the process the boiler will be boxed up for slow cooling, drained and
flushed free of residues with hot water followed up by cold water flushing.
5.2.2 Acid Cleaning
For all High pressure units the alkali boil out will be followed up by acid cleaning. There are
two methods in vogue for acid cleaning :
i) Soaking method.
ii) Circulation method,
In the soaking method, the internal surfaces of the boiler are kept soaked in inhibited acid
solution for 4 to 6 hours after firing the unit to raise temperature. In the circulation method the
inhibited acid solution is maintained under circulation for 4 to 5 hours by means of acid
circulation pumps and a temporary circulating system of dissolving tank and piping. Required
water temperature is maintained by addition steam from external source in the dissolving
tank. In both methods inhibited acid is used for preoperational cleaning.
Fig. XXIV-1 gives a scheme of circulation system adopted for circulation method which is
commonly practised for acid cleaning. In this method use system is first filled with
dernineralised water and temperature raised to the required value by adding steam to the
dissolving tank. The flow required is maintained under circulation. Inhibitor is first added to
the circulating water followed by acid. Ammonium bi-fluride is sometimes added to increase
the reaction rate and to dissolve silica. The solution is kept under circulation by operating the
pumps. Samples of circulating water are taken every 15 minutes from different locations and
analysed for acid concentration (percentage), pH value, silica, and iron contents.
The process is terminated, when the iron concentration stabilises. Normally this will happen
in about 4 hours. At this stage the system is drained under positive nitrogen pressure, and
rinsed with demineralised water. To ensure thorough iron removal this rinsing may be followed
by similar cleaning with citric acid.
The system is then drained under nitrogen capping and rinsed till no traces of acid are detected
in the sample.
After rinsing neutralisation may be done with an alkaline chemical like soda ash. Finally in
the passivation stage the chemicals (normally hydrazine and ammonia) are added to the hot
circulating water and circulation is maintained for a pre-determined period after which whole
system is drained hot. The complete system is well ventilated by opening all the vents and
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manholes. Throughout the acid cleaning process the superheaters are filled with treated D.M.
water and pressurised. Once the surfaces are sufficiently cool the internal surfaces of the
system should be inspected for cleanliness and passivation coating.
Chemical cleaning of the unit removes some weld slag also. Hence after cleaning, the
boiler must be checked for weld sweating or leakages. This is best done by hydraulic
testing of the unit.
The passivation coating created immediately after acid cleaning will be lessadherent. To
achieve permanent base protection layer, second stage passivation is carried out at a
temperature of about 250
o
C. This is achieved by firing the boiler and raising the pressure to
about 40 kg /cm
2
with adequate content of hydrazine as the prime chemical.
5.3 Thermal Flow Test
Thermal flow test is conducted to detect passage obstruction in waterwall, economiser and
superheaters. The chocked tube is identified with the help of thermal flow meter using the
principle that the rate of cooling of a heated tube depends upon the fluid flow rate inside the
tube. The thermal flow meter used in the test Measures the time taken for a heated tube to fall
in temperature from 10
o
C above the ambient to 3
o
C above ambient. This timing for the different
tubes of the circuit is compared for detecting the chocked tubes.
For conducting the test, a flow circuit should be established and flow maintained so as to
create the required velocity in the tubes to be tested. For obtaining reasonably accurate results
a minimum velocity required is 0.1 m/sec. Normally the acid cleaning circuit and pumps used
will be sufficient for the purpose. While conducting test in the waterwall, the downcomers
are to be blanked for obtaining satisfactory velocity in the waterwall tubes.
It is advantageous to carry out the test in the waterwall and economiser immediately before
the acid cleaning and in the superheater system after blowing.
When testing superheaters only volatile chemicals should be used for treating the demineralised
water. It is essential to take necessary precaution to avoid water going to the turbine side.If
main steam line is filled up with water, the hangers should be locked.
5.4 Steam Blowing
Steam blowing operation is intended to remove mill-scales, welding slag, debris or other
foreign material left over in the superheaters, reheaters and steam piping. The basis behind
steam blowing is to create a momentum equal to or preferably greater than that during normal
operation. This will blow out all the loose debris from the system. The two methods in practice
for steam blowing are puffing method and continuous blowing. In the puffing method a thermal
shock is created which helps in dislodging the scales from the internal surfaces.
In the continuous blowing method constant purge steam rate is maintained by firing the unit
for few minutes, whereas in puffing the fire is quenched and pressure is allowed to decay
during blowing. As the pulling method is Most commonly employed, only this method is
described here. Refer Fig. XXIV-2 for scheme generally adopted for steam blowing. The
boiler is filled up to the normal level with treated D.M. water. Pressure is raised by firing to
about 40 atmospheres, and firing discontinued. The outlet valves in the steam lines are opened,
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venting out the steam to atmosphere. The high differential pressure between boiler and
atmosphere creates a high Mass flow of steam at velocities much higher than normal. When
the pressure drops down to about 25 atmospheres the valves are closed and the firing restarted
to raise the pressure again for the next blow. The cycle is repeated till the lines are adequately
clean. As every blow induces a thermal shock to the boiler components, the pressure drop
during each blow should be limited to about 40
o
C drop in saturation temperature.
The effectiveness of steam blowing is evaluated by a target plate placed in the stream near the
outlet to atmosphere. As the main object of blowing is to prevent damage to turbine blades
from foreign materials carried by steam the target plate also is to be made from similar Material
as that of turbine blade. Blowing should be continued till clean targets are obtained.
5.5 Safety Valve Setting
At the end of steam blowing, the safety valves in the boiler will be floated and set to operate
at the required pressure. This is done to ensure the availability of the safety valves for pressure
release in times of necessity and also to check the sturdiness and adequacy of the venting
system.
During safety valve setting the boiler steam pressure will be raised to the Maximum value for
the first time. In Most cases the safety codes require this to be done in the presence of boiler
inspector.
Before commencing floating all the pre-commissioning checks and servicing of the valves
should have been completed. The boiler pressure is gradually raised at much lower rate than
normally recommended in start up curve to facilitate measuring waterwall and other pressure
part expansions. The waterwall expansions would be proportional to saturation temperature
rise corresponding to boiler pressure. Free expansion and expansion clearance at different
locations should be carefully checked. The expansion data is collected for different pressures
including the full operating pressure.
After measuring the expansion at operating pressure, all the safety valves (except the one to
be floated) are gagged. When the boiler pressure is around 10% lower than the set value, the
valve is warmed up and eased by hand popping. Then the pressure is gradually raised. When
the safety valve floats the pressure is noted down using a calibrated gauge and the firing
stopped. As the boiler pressure decays, the safety valve reseating pressure is also noted. Any
adjustment required for setting the lifting pressure or blow down is done as per the safety
valve 0 & M manual. Then the firing is restarted and pressure raised. The procedure is repeated
till the safety valve lifting pressure and blow down are within acceptable limits.
The above procedure is repeated for all safety valves. If floating Is started from the valve set
at highest pressure, and proceeded in the order of decreasing set pressure, gagging of already
floated safety valves will not be normally required. Before declaring the completion of this
operation gags from all the safety valves should be removed and accounted.
5.6 Clean Air Flow Testing of Pulverisers
Pulveriser clean air flow test is conducted for the following purposes:
a) To verify correct orifice installation in pulveriser fuel pipes.
b) To check that coal pipes and riffle distributors are free from foreign
Materials.
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c) To check if the exhauster (of suction type mills) has sufficient head to assure
100 per cent air flow at 100 per cent mill loading.
d) To calibrate the venturi or piccolo or jam tubes for mill air flow measure
ment (in pressurised mills).
Before commencing the test, all the pre-commissioning checks on the pulveriser should
have been completed and the primary air system commissioned.
For pressurised mills the test is conducted as follows:
i) F.D. and W. fans are started and normal furnace draft maintained.
ii) The primary air fans are run and the required hot primary air header to furnace
differential and mill air flow is maintained.
iii) Air flow through the pulverised coal pipes is measured by a standard pitot tube and
adjusted by operating hot air and cold air dampers to obtain approximately standard
mill air flow.
iv) The velocity profile in each of the coal pipes is accurately measured by using a
standard pitot tube.
v) The mill Bowl differential and the air flow measuring instrument differentials are
also measured.
All these data are recorded in a test format.
From the above readings the air flow through each pipe is calculated and the variation in
percentage from the average is computed. This should be within + 5%. If the variation is
higher, then the coal pipes should be checked for any foreign materials or incorrect orifice.
After correcting the problem the test is re-run until desired results are obtained.
From the data collected the calibration curve for the flow measuring instrument, is also
computed and furnished to the instrumentation supplier for setting the mill air flow control
system.
Completion of clean air flow test marks the readiness of mills for operation on coal.
5.7 Testing of Protections and Interlocks
Protection and interlocks do the very important function Of safeguarding the equipments
from damages due to malfunctioning or mal-operation. All the interlocks and protections
provided for the individual equipments should necessarily be checked, and made functional
before trial run of equipments.
The protection interlocks are normally supplied by electrical and instrument contractor to the
design of project engineering consultants. Boiler commissioning engineer prepares the full
list of approved final interlocks and protections envisaged for different equipments and systems.
A detailed sequence of testing (simulation as well as actual testing wherever possible)
envisaging all conditions is also prepared. Testing is done jointly with the concerned agencies.
Observations and adjustment done are recorded. Defects if any should be rectified. The testing
should be repeated till all the protections and interlocks are checked and ensured.
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5.8 Calibration of Instruments
All the instruments both at local and in unit control board should be calibrated before putting
them into service. Pressure gauges should be calibrated by dead weight gauges. Draft gauges
should be checked with local manometers. Temperature indicators may be compared with
thermometers and thermocouples should be read by potentiometers. Flue gas oxygen readIng
should be verified with Orsat analysers.
Normally test pockets are provided at different locations for the purposes. At critical locations
like Economiser water inlet, Superheater outlet, Reheater outlet and Desuperheater inlet and
outlet, Calibrated. Thermocouples should be fixed in the test pockets for periodic reading and
comparison with UCB indication till the reliability of the UCB indication is established. Air
heater gas inlet and outlet ducts should be fitted with grids for multipoint measurement of
temperature and oxygen content in flue gas.
6. TRIAL OPERATION OF BOILER
Satisfactory completion of precommissioning activities is a milestone in commissioning. This
indicates the readiness of boiler for Trial operation. At this time all facilities and inputs for
loading the unit and putting into regular service should be ready. For utility units the turbine
generator and the complete electrical transmission system must be ready- In the case of
industrial boilers the process equipments should be ready. Before trial run of the boiler a
general inspection of all equipments is carried out. All the rotating equipments are checked
for proper lubrication and smooth operation. Dampers, and valves are rechecked for proper
operation. The complete instrumentation and control must be checked for proper functioning.
The automatic controls should be checked and made ready for commissioning. Adequate
number of operating and maintenance staff and good communication between different areas
and the control room must be ensured. The boiler is then lighted up in accordance with operation
and maintenance instructions.
The rate of pressure rise, furnace outlet temperature and any other limitation given in the 0 &
M instructions should be strictly adhered to. The unit is then loaded and the load raised
according to starting diagrams given in the operating instructions. During the first few start
ups it may be worthwhile to raise the load at a slower rate, in order to acquaint the operators
with the behaviour of various systems. The milling system can be tried one after the other.
After checking for smooth working of the mills without undue vibration, noise, pounding or
temperature rise, the unit load can be increased progressively. All the automatic controls
including the furnace draft, drum level, total airflow, steam temperature and milling system
automatics are commissioned and put into operation progressively. Combustion regime
adjustments can be taken up at this stage for optimising milling system performance and
setting up secondary air damper controls.
The main activity in optimising milling system performance is to set classifier to obtain the
required fineness. For large utility boilers the recommended pulverised fuel fineness is 70 per
cent passing through U.S. 200 Mesh. However in some cases adjustments may be required at
site due to varied burning characteristics, slagging tendency or abrassiveness of coal being
fired. Any adjustment should aim at obtaining minimum carbon loss and least wear of milling
system components. To start with the Mill classifier vanes May be positioned in the middle of
their operating range and Mill loaded to its full design capacity for the coal being fired. The
Mill air flow and Mill outlet temperature must be maintained as per design recommendations.
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After the Mills have stabilised, pulverised coal sampling is conducted as given in the operating
instructions. Simultaneously bottom and fly ash sample should be collected. The furnace
must be visually checked for proper combustion and flame stability. If fineness vary
significantly from recommended values classifier is adjusted suitably till optimum conditions,
i.e., good combustion, acceptable carbon loss and least wear of milling system components
are obtained. After the trials fineness must be recorded and intimated to all concerned.
Optimising the milling system may be followed by setting the secondary air dampers. Secondary
air dampers serve to proportion the combustion air between fuel and auxiliary air. In tangential
firing system, more fuel air tends to shift the coal ignition point away from the tip and vice
versa. For reliable operation the coal ignition point must be adjusted for obtaining stable
ignition of coal at all feeder speeds and a healthy scanner, pick up. This is achieved by stroking
the fuel air dampers in tune with feeder speed between a minimum and a maximum opening.
The maximum and minimum limits of fuel air damper opening and the recommended wind
box pressure should be checked before commissioning the secondary air control system on
automatics.
Before taking the unit upto full load, the boiler should be maintained at different loads to
check the performance of individual equipments as well as the systems. At different loads the
superheater metal temperature distribution should be measured and recorded. Water and steam
temperatures, air flows, oxygen content in flue gas entering and leaving air heaters should be
periodically checked locally with reliable instruments and cross checked with control room
indication.
While raising load, the different regimes and parameters should be maintained as
envisaged in the design of equipments and their performance watched. Any problems in
this regard should be intimated to the designer for analysis and solution. This feed back is
essential for the designer to know the equipment performance and for improving the
equipment.
When the unit is fully loaded and the performance is satisfactory the boiler is
declared ready for trial run. During the trial run the boiler is operated according to the load
requirements agreed between the owner and the supplier in accordance with the contract
terms. Normally during trial run the boiler is operated at varying loads for sometime and at
full load for a specific period.
On successful completion of trial run the boiler is declare rteady for commercial
operation and taken over by the operation group. Even at this stage there can be some
minor pending points or problems which deo not affect the safe operation of the unit . the
concerned agencies may agree to attend to these problems at the next oppurtunity even
after the boiler is taken over.

B A C K
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7. PERFORMANCE TESTING
The test is normally carried out within 3 months or as agreed upon after declaring the
boiler for commercial operation. Generally when more than one unit is supplied under the
same contract, the testing will be done on one unit only. The conditions for the test are
normally agreed at the contract stage itself. For details of conducting performance test, the
relevant chapter may be referred.
8. TRAINING OF OPERATING AND MAINTENANCE STAFF
Training of operating and maintenance personnel is best done during commissioning of
the boiler.
A well-planned programme result in correct operating and maintenance procedures being
followed.This will reflect in high availability of the unit.The training programme should
be devised to acquaint the operators and engineers in
1. Basic theory.
2. Constructional features.
3. Equipment operation - Regular and emergency situation.
4. Adjustment and maintenance procedures.
Basic document for use in training is the operating and maintenance instructions of the
equipment. The relevant sections should be completely read and understood by all operating
and maintenance personnel. The information may be supplemented by lectures from designers,
commissioning engineers and experienced operating personnel. Visits to running stations
and sites during erection of the equipment will greatly help in the understanding of the
equipments.
The operation and maintenance personnel should be identified well in advance so that they
can participate in the commissioning of the equipments. They should be associated with
commissioning engineers right from initial stages. After completion of trial runs the equipment
can be operated by the operating staff under the guidance of commissioning engineers.
This mode of training normally results in better understanding of the equipments and their
behaviour by the operating staff much before the units are ready for commercial operation.
This procedure is also advantageous in that the operating and maintenance personnel will
know of all the problems faced with the equipments during commissioning and their solutions.
Completion of trial run or the performance test marks the successful commissioning of the
unit.
After successful commissioning and handing over, a document highlighting the various
activities, problems faced, record of data collected and protocols signed should be prepared
and sent to all the agencies for their records.
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FIG. XXIV-1 SCHEME OF CHEMICAL CLEANING
(INFORMATIVE)
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FIG. XXIV-2 STEAM BLOWING - PUFFING METHOD
FOR REHEAT BOILERS
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