Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 1 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
SLNO
LIST OF CONTENTS
1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PERECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

10.0

APPENDICES
a) LOG SHEET
b) CHECKING AND COMMISSIONING OF VFD.

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 2 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
1.0

PLANT DETAILS:
The plant details of the Draft System is as follows.

1.1

Induced Draft Fan

1.2

No of Fan

: 2

Type

: NDZV 47

Make

: BHEL

Flow

: 558.2 cu.m/Sec

Pressure

: 485 mmwc

Temperature

: 1530C

Drive

: Motor

Speed

: 580 RPM

Motor Rating

: 3650

Control

: Inlet Damper plus variable

Frequency Drive. (VFD).

Forced Draft Fan

No. of Fan

: 2

Type

: Axial AP 1-26/16 Axial

Reaction, single stage with
Silencer.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 3 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
Make

: BHEL

Flow

: 246 cu.m/Sec

Pressure

: 351 mmwc

Temperature

: 500C

Drive

: Motor

Speed

: 980 RPM

Motor Rating

: 1175 KW

Control

: Variable Blade Pitch control.

The boiler is also equipped with primary air fan, which form a
part of the coal preparation and firing system.
1.3

Primary Air Fan

No. of Fan

: 2

Type

: Axial AP 2-20/12
Axial Reaction, Double
stage with silencer

Make

: BHEL

Flow

: 170.5 cu.m/Sec

Pressure

: 1183 mmwc

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 4 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
Temperature

: 500C

Drive

: Motor

Speed

: 1480 RPM

Motor Rating

: 2450 KW.

Control

: Variable Blade Pitch

Control.

1.4

All the fan are mounted on concrete deck with suction and
discharge duct. Connected to the Fan flanges. FD Fans and PA
fans are provided with Silencer at the suction duct. Regulation of
Fan from no load to full load is performed by changing the pitch
angle of blade profile on all blades simultaneously during
operation. This is achieved through a sophisticated servo
mechanism (Hydraulic Servo Motor) externally actuated by a
power cylinder or Servomotor and forced lub-oil system.

1.5

In the case of ID Fan, the equipment is driven by variable

frequency drive motor coupled with soft coupling. The regulation
of the fan is effected through the inlet dampers located at the inlet
of the fan and variable speed by VFD.

1.6

In FD and PA fans, the rotor is supported in antifriction bearings

and cooled by forced lubricating oil. A thrust bearing is provided
to absorb axial loads. Thermometers are provided in the bearing
housing for temperature monitoring.

1.7

In ID Fan, the bearings are white metal sleeve type with forced oil
lubrication. Fixed bearing near drive end is designed to absorb
the Axial forces. Thermometers are provided in the bearing
housing for temperature monitoring.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 5 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
1.8

Respective O & M manuals to be referred for typical drawing of

each fan.

1.9

List of plant Item readiness (Mechanical, Electrical and C&I) are

to be prepared at site before commissioning of the fans.

1.10

Safety Rules clearance certificate to be signed at site before

commissioning of the fans.

2.0

OBJECTIVE:
To commission the fans (ID Fan, FD Fan and PA fan) and make it
available for commissioning and operation of the Unit.

3.0

PROPOSAL
It is proposed to commission the fans as per the following
proposals.

3.1

Oil flushing of lub-oil system (Refer to Testing schedule BHEL

Ref.No PS-DC-186-500-0013A/SIM/1/TS/1/003A)

3.2

Trial run of H.T. Motor for 8 Hrs.

3.3

Trial run of Fan for 8 Hrs.

4.0

SERVICES REQUIRED

4.1

Availability of O & M Manual for fans

4.2

Availability of auxiliary cooling water

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 6 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
4.3

Availability of L.T/H.T. Power supply

4.4

Availability of lighting, communication facility at the test area.

4.5

Availability of portable fire extinguishers

4.6

Availability of working crew with Technician for attending minor

problem during commissioning of Fans.

5.0

SAFETY PRECAUTIONS:

5.1

Availability of first aid kit at test area.

5.2

The team commissioning the fan should be aware of the

procedure adopted.

5.3

Agencies working in the boiler area / associated ducting system

are informed about the test / cleared from the test area (As per
the actual requirement).

5.4

All loose materials around the fan area are cleared.

5.5

Required approach stair cases, platforms and hand rails are

erected prior to testing.

5.6

Oil collecting trays and sand buckets are made available at test
area.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 7 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
6.0

EMERGENCY PRECAUTIONS:

6.1

The group conducting the test should be aware of action to be

taken on the event of injury to personnel.

6.2

The group shall be aware of operating instruction of portable fire

extinguishers.

6.3

The test team should be aware of the steps to be taken to trip the
running equipment in case any emergency / abnormal
observations are notified to them.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 8 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
7.0

STATE OF THE PLANT

7.1

Erection of the following are completed.

Lub oil system
All the lub oil control oil pipe lines
C.W lines
Fan and its H.T.Motor
Suction and discharge duct and their connection with fan.
L.T./H.T switch gears required for the fan.

7.2

Fan casing, Suction / Discharge ducts are cleared off men &
temporary materials.

7.3

All permanent supports and guides of fan & duct are erected.

7.4

All local instrumentation of lub-oil system, motor and fan are

erected. (Required list to be prepared at site) )Pressure and
temperature indicators are duly calibrated)

7.5

Remote indication at control room are made available (List to be

prepared at site)

7.6

Recommended lubrication oil is filled up in the lubrication system.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 9 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
7.7

Blade pitch operation (for FD & PA fan) and inlet damper

operation for ID fan) verified at local and the same ensured from
remote for correct opening / closing with respect to position
indicator at local and remote. Free movement of Blades & inlet
dampers are ensured.

7.8

ACW lines are flushed and connected to the respective inlet

points.

7.9

ACW inlet / outlet connections to ID fan sleeve bearings are

connected as per the indicated markings.

7.10

Ensure variable frequency Drive (VFD) system is made ready (In

case of ID Fan for operation of the Fan. (Refer to the procedure
enclosed in Section 10.0.)

7.11

Insulation resistance of the motor measured and ensured that the

values are at satisfactory level.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 10 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
8.0

METHOD

8.1

Start lub-oil system and establish oil circulation at recommended

oil pressures (Both lub-oil and control oil, which ever is
applicable)

8.2

After obtaining clearance from all agencies, start the motor in

decoupled condition and check the direction of rotation. If
direction found reverse, change the direction of rotation of the
motor.

8.3

Refer to section 10.0 for details regarding checking and

commissioning of VFD system. In addition commissioning manual
of VFD issued by supplier to be followed in the commissioning of
VFD system.

8.4

Start the motor once again and put under 8 Hrs trial run (FD and
PA motors). In the case of VFD synchronous Machine, put the
machine under 4 Hrs trial through channel I and under 4 Hrs trial
through channel II.

8.5

Performance of the motor to be monitored by logging load

current, vibration and temperatures of bearings and windings,
whichever applicable.

8.6

After satisfactory completion of drive trial run, drive and the fan
are coupled.

8.7

Start the fan and put under 8 Hrs trial run.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 11 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
8.8

Blade pitch for FD and PA fan to be at minimum before starting

the fan and after starting, fan to be slowly loaded up to around
10-15% (Exact loading of the fan to be decided at site)

8.9

For ID Fan, keeping the inlet damper at minimum, Fan started

and loading to be gradually increased to 10-15% (Exact loading
of the fan to be decided at site)

8.10

During 8 Hrs trial run, Fan performance observed by logging load

current, vibration, temperatures of the bearings, parameters of
lub-oil system VFD system and draft values in PA,SA and Gas
circuits covered in single fan running condition.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033

NTPC Ref no SIM/1/TS/1/33

Sheet 12 of 15

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)
STATUS
SL.NO
9.0

COMPLETION CRITERIA
Commissioning of Fan (ID Fan, FD fan and PA Fan) completed
with satisfactory completion of
a) Oil flushing of Lub-Oil system
b) Trial run of motors for 8 Hrs
c) Trial run of Fan for 8 Hrs.
(8 Hrs trial each for motor and Fan of FD and PA system and 8
Hrs trial for motor and Fan of ID system with channels I ans II
each inservice for 4 Hrs duration)

10.0

APPENDICES:
a) Log Sheets.
b) Checking and Commissioning of VFD

Signatures
NTPC

BHEL

PROCEDURE FOR COMMISSIONING OF FANS

(ID FAN, FD FAN AND PA FAN)

SHEET 13 OF 15
10.0

LOG SHEET
DATE :

Project :
Unit
:
Activity :

LUB-OIL SYSTEM
SL
No

TIME

Discharge
Pressure

Filter
DP

Control
Lub-Oil
oil
Pressure
pressure

BEARING TEMPERATURE
Oil
Temp
after
cooler

Tank
Oil
Level

Motor
DE

NDE

Fan
DE

NDE

Draft
(Suction/
Discharge)

Signatures
NTPC

BHEL

Remarks