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PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HL-002

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI

CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power Commissioning & PLTU 1 Jatim-Pacitan (2×315MW)
DESIGN STAGE
Test Institute Project

Approval Check
Procedure of Air Preheater System
Review Design
Date Scale N/A DWG No. SCCTI-TS-GL-CS-012-2009A REV A
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Commissioning
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Table of Contents

1. PURPOSE ..............................................................................................................................................................3

2. SCOPE ...................................................................................................................................................................3

3. PREPARATION BASIS.........................................................................................................................................3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .................................................................................3

5. TOOLS AND INSTRUMENT FOR COMMISSIONING.....................................................................................4

6. PREREQUISITE FOR COMMISSIONING .........................................................................................................4

7. MEASURES FOR COMMISSIONING ORGANIZATION .................................................................................6

8. COMMISSIONING PROCEDURE ......................................................................................................................7

9. SAFETY MEASURES ........................................................................................................................................14

9.1 Safety Rules for Commissioning.......................................................................................... 14

9.2 Personal Risk and Preventative Measures............................................................................ 14

9.3 Equipment Risk and Preventative Measures ........................................................................ 14

10. APPENDIX ........................................................................................................................................................14

Appendix 1 Commissioning Condition Checklist...................................................................... 15

Appendix 2 Parameter Record for Trial Run of APH and Its System........................................ 17

Appendix 3 Commissioning Record Format of Dampers of APH System ....................... 19


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1. Purpose
1.1 Provide a guideline and set specifications for the commissioning work of system and
equipment so as to guarantee that the system and equipment will be able to put into operation
normally and safely.
1.2 To check electric and I&C protection, interlock and signal devices and confirm their proper
operation.
1.3 To check equipment running, verify system performance, and detect and remove any potential
defects.

2. Scope
This procedure is applicable to sub-system commissioning of air preheater(APH) system. The
commissioning starts from dynamic taking over and acceptance after completion of individual
commissioning of APH, including the items of damper baffle confirmation, test of interlock
protection, system in service and dynamic adjustment.

3. Preparation Basis
3.1 Boiler equipment operation manual and flue-gas and air system chart.
3.2 Operation and Maintenance Manual of Air Preheater
3.3 Installation Manual of Air Preheater
3.4 Local control cabinet manual and design drawings of APH.
3.5 Purchased equipment manual and design drawings of APH.

4. Brief Description of System and Equipment


4.1 There are two sets of APHs both for operation. Vertical model is used; the structure is
Tri-sectional regenerative and the flue gas flows downwards.
4.2 Seal of APH
The radial, axial and circumferential seal system is used in APH and the double seal structure
of radial to axial and radial to bypass which has a short perimeter and proper effect. It is also
equipped with seal clearance automatic tracing control device which has an automatic thermal
compensation with reliable electronic sensing element. The double seal system can make each
fan shape plate, at least there are two plate of radial and axial seal device to coordinating at
any time when the rotor rotates to form two courses of seal which makes the pressure
differential at the seal place reduce to half and the air leaking is directly dropped to about 30
%.
4.3 Wash device and fire alarming system of APH
The fixed flushing pipelines are provided on hot end and cold end of the flue gas side of each
APH respectively. The flushing pipeline is installed at the startup side near the flue gas side as
per the rotation direction of the rotor to facilitate the flushing water to be drained from the ash
hopper at the flue gas side. The flushing media is constant temperature industrial water P=
0.59MPa. If water with temperature of 60~70℃ is used, the washing effect can be much
better. The flushing pipeline is also used for fire fighting.
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The fire alarm system is a horizontal shifting and infrared ray monitored installed in the air
side of the lower part of APH and has a good monitoring effect.
4.4 Soot blower of APH
An expansion soot blower with forward intermission and backward direct-acting is installed
in cold end of the flue gas side of each APH. The steam source for soot blower comes from
the header of platen superheaters and auxiliary steam.
4.5 Technical Parameters of APH

Model: 29VNT1920 Main motor Auxiliary motor


Model: Y160L-6B5 Y160L-6B5
Power 11KW 11KW
Voltage 380V 380V
Current 24.6A 24.6A
Motor rotation speed 970rpm 970rpm
Insulation class B B
Air preheater rotation speed 1.14rpm 0.507rpm
Manufacturer Dongfang Boiler Group Co,. Ltd.

5. Tools and Instrument for Commissioning


5.1 Walkie talkie
5.2 Digital multimeter

6. Prerequisite for Commissioning


Before formally beginning system commissioning, commissioning persons should conduct
comprehensive checks on conditions that should be available for commissioning of this
system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and
make well the records.
6.1 Environmental Conditions
The ground within the system shall be level, the road free, covers for the trench complete and
the environment is clean without sundries.
The platforms, ladders, railings and guard sheets within the range of the system shall be
complete and the scaffoldings have been removed completely.
6.1.1 There shall be enough permanent illumination and temporary illumination shall be provided,
if necessary.
6.1.2 There is reliable communication equipment at the site.
6.1.3 There are enough fire fighting apparatuses available at the site.
6.2 Conditions that must be available for machinery provisions
6.2.1 The installation of insulations for equipments, pipelines and auxiliary system of APH is
completed.
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6.2.2 Single trial run of APH is qualified.


6.2.3 The installation and commissioning of the thin oil station is completed.
6.2.4 The oil level in redactor is normal and operation of the pump of the redactor is normal.
6.2.5 The installation and commissioning of the industrial cooling water system is completed.
6.2.6 The sundries inside the APH and its system are cleaned completely.
6.2.7 The installation and commissioning of alkali flushing system of APH is completed.
6.2.8 The name plates for equipments and valves are already tagged and matched to the system.
6.2.9 Doors of all manholes in the system are closed.
6.3 Conditions that must be available for electrical and I&C
6.3.1 The measurement points and measurement elements inside the fuel oil system have been
successfully installed and commissioned after the calibration is satisfactory and ready for
operation.
6.3.2 The commissioning of thin oil station is completed and a proper operation is confirmed, the
parameter is normal and CRT status indication is correct.
6.3.3 Commissioning of clearance adjustment device of APH is completed.
6.3.4 Commissioning of fire alarming device of APH is completed
6.3.5 The commissioning of single valve is completed, the open and close action is normal, the
local position and CRT status indication of limit switch is correct.

6.3.6 Test of interlock protection alarm of APH is completed.


6.3.7 Electrical test of motors is qualified, idle run for 2h and operation is proper and rotating
direction is correct.
6.4 Other preconditions required to be available
6.4.1 The parties of Dongfang Electric, Owner, production and commissioning had been organized
to conduct the large joint inspection, the problem, if found any, was rectified.

6.4.2 The preparation for production trial run has been completed and enough numbers of operators
have been deployed and trained and passed the examination. The operation regulations and
system chart have been approved, operation tools are available and the operation log is ready.
6.4.3 Prepare maintenance tools and materials necessary for commissioning;
6.4.4 The commanding organization of the trial run is established and work division is clear.
The materials, tools, instruments, meters and record formats to be used in commissioning are
ready and complete.
6.4.5 The commissioning personnel concerning I&C, electrical and mechanical of the installation
contractor are available at site.
6.4.6 The clarification of measures is completed.
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7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows:
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;
◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;


◆ Hold technical disclosure meeting for commissioning;
◆ Organize the commissioning work to be carried out by various parties;
◆ Give instructions to operators in the operation;
◆ Prepare commissioning report.
7.2 Responsibilities of Installation Contractor
◆ Be responsible for individual commissioning of equipment and provide relevant record
and certificate of commissioning;
◆ Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;


◆ Be responsible for temporary coordination of local I&C components and connection
terminals.
7.3 Responsibilities of Equipment Manufacturers
◆ Representative of manufacturer, if present on the site offering service, shall provide
technical assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator
◆ Prepare tools to be involved in operation;
◆ Prepare operation log and forms;
◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;
◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;

◆ Be responsible for dealing with the accidents occurred in commissioning。


7.5 Responsibilities of Dongfang Electric
◆ Be responsible for supervision and control over commissioning work;
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◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning。


7.6 Responsibilities of Owner
◆ Supervise the execution of commissioning procedures;
◆ Witness the commissioning work;

◆ Accept the results of commissioning。

8. Commissioning Procedure
8.1 Check and accept flue gas and air baffle and record the following data:
Check for correctness of KKS code, designation, local position indication, remote operating
direction, feedback, time used in open and close of damper, signature of person concerned.
Refer to Appendix 2.
8.2 Interlock Protection and Alarms Check (Note: the result of logic discussion will prevail for
the test items of the interlock protection).
8.2.1 Place the power supply to the test position and check the following items:
(1) APH is started up by a computer and the feedback is correct.
(2) APH is shut down by a computer and the feedback is correct.
(3) The work of emergency button is reliable.
8.2.2 Check for alarm signal of APH A (B)

Remark
No. Test item Fixed value Results
s
Check of alarm signal of APH A
(1) Alarm from fire detector of APH A
(2) Rotor rotating of APH A stop
(3) Alarm of guidance bearing temperature≥70℃of APH A
(4) Alarm of thrust bearing temperature≥70℃of APH A
(5) Alarm of guidance bearing oil station failure of APH A
(6) Alarm of thrust bearing oil station failure of APH A
Check of alarm signal of APH B
(1) Alarm from fire detector of APH B
(2) Rotor rotating of APH A stop
(3) Alarm of guidance bearing temperature≥70℃of APH B
(4) Alarm of thrust bearing temperature≥70℃of APH B
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(5) Alarm of guidance bearing oil station failure of APH B


(6) Alarm of thrust bearing oil station failure of APH B

8.2.3 Check for permissive conditions for APH A (B) Startup

No. Test item Fixed value Results Remarks


Check of permissive conditions of APH A startup
(1) No APH integrated troubles in APH A
(2) Auxiliary motor of APH A has been shut down
(3) Power supply for main motor of APH A not broken
(4) Main motor of APH A on remote control state
(5) Main motor of APH A shutdown
(6) Oil station of guidance bearing of APH A ready
(7) Oil station of thrust bearing of APH A ready
(8) Reductor oil pump of APH A shutdown
Check of permissive conditions of APHB startup
(1) No APH integrated troubles in APH B
(2) Auxiliary motor of APH B has been shut down
(3) Power supply for main motor of APH B not broken
(4) Main motor of APH B on remote control state
(5) Main motor of APH B shutdown
(6) Oil station of guidance bearing of APH B ready
(7) Oil station of thrust bearing of APH B ready
(8) Reductor oil pump of APH B shutdown

8.2.4 Permissive conditions for APH shutdown

No. Test item Fixed value Results Remarks


Permissive conditions for APH A shutdown
(1) Inlet flue gas temperature of APH A <205℃
(2) Both ID fan A and FD fan A shutdown
Permissive conditions for APH B shutdown
(1) Inlet flue gas temperature of APH B <205℃
(2) Both ID fan B and FD fan B shutdown
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8.2.5 Termination conditions for interlock protection of APH

No. Test item Fixed value Results Remarks


Termination conditions for interlock protection of APH A
(1) emergency button in motion
(2) Reductor oil pump of APH A tripped
Termination conditions for interlock protection of APH B
(1) emergency button in motion
(2) Reductor oil pump of APH B tripped

8.2.6 Startup condition for interlock of main and auxiliary motors of APH
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No. Test item Fixed value Results Remarks


Startup conditions for main and auxiliary motors interlock of APH A
(1) Under the standby in service conditions, the auxiliary
motor of APH A failed or shutdown and the
corresponding main motor is started up by interlock.
(2) Under the standby in service conditions, the auxiliary
motor of APH A failed or shutdown and the
corresponding auxiliary motor is started up by interlock.
Startup conditions for main and auxiliary motors interlock of APH B
(1) Under the standby in service conditions, the auxiliary
motor of APH B failed or shutdown and the
corresponding main motor is started up by interlock.
(2) Under the standby in service conditions, the auxiliary
motor of APH B failed or shutdown and the
corresponding auxiliary motor is started up by interlock.

8.2.7 Interlock test of outlet primary and secondary dampers and inlet flue gas baffle of APH

No. Test item Fixed value Results Remarks


(1) Main motor or auxiliary motor of this side APH is in
operation and the outlet primary and secondary dampers
and inlet flue gas baffle are opened by interlock
(2) At the request of FSSS natural draft, delaying for 15s,
the outlet secondary damper and inlet flue gas baffle are
opened by interlock
(3) Main motor or auxiliary motor of this side APH is out off
operation and there is no request of natural draft from
FSSS, the outlet primary and secondary dampers and
inlet flue gas baffle are closed by interlock

8.2.8 Interlock Protection Test of APH Oil Station(B is same as A)

No. Test item Fixed value Results Remarks


Oil station interlock protection of APH A
(1) Standby pump is started up by interlock when oil pressure
is low (0.12MPa)
(2) Oil pump failure, standby pump is started by interlock and
failure alarms
(3) Standby pump is shut down when oil pressure high
(0.3MPa)
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(4) Alarming and automatically starting up the pump when the


guidance bearing temperature is high(>55℃)
(5) DCS alarms when guidance bearing temperature is HH
(>70℃)
(6) Pump automatically shutting down when guidance bearing
temperature is low (<45℃)
(7) Standby pump automatically starting up when the support
bearing temperature is high (>55℃)
(8) DCS alarms when support bearing temperature is HH
(>70℃)
(9) Pump automatically shutting down when support bearing
temperature is low (<45℃)
Oil station interlock protection of APH B
(1) Standby pump is started up by interlock when oil pressure
is low (0.12MPa)
(2) Oil pump failure, standby pump is started by interlock and
failure alarms
(3) Standby pump is shut down when oil pressure high
(0.3MPa)
(4) Alarming and automatically starting up the pump when the
guidance bearing temperature is high(>55℃)
(5) DCS alarms when guidance bearing temperature is HH
(>70℃)
(6) Pump automatically shutting down when guidance bearing
temperature is low (<45℃)
(7) Standby pump automatically starting up when the support
bearing temperature is high (>55℃)
(8) DCS alarms when support bearing temperature is HH
(>70℃)
(9) Pump automatically shutting down when support bearing
temperature is low (<45℃)

8.2.8 Startup Sequence of APH A Sub-group (B is same as A)

No. Test item Fixed value Results Remarks


Startup sequence of APH A
(1) First step: startup oil station of APH
(2) Second step: startup main or auxiliary motor of APH
(3) Third step: open secondary air outlet damper of APH
(4) Fourth step: open flue gas inlet baffle of APH
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Startup sequence of APH B


(1) First step: startup oil station of APH
(2) Second step: startup main or auxiliary motor of APH
(3) Third step: open secondary air outlet damper of APH
(4) Fourth step: open flue gas inlet baffle of APH

8.2.9 Shutdown Sequence of APH A Sub-group (B is same as A)

No. Test item Fixed value Results Remarks


Shutdown sequence of APH A
(1) First step: close flue gas inlet baffle of APH A
(2) Second step: close primary and secondary air outlet
dampers
(3) Third step: shutdown main or auxiliary motor of APH A
Shutdown sequence of APH B
(1) First step: close flue gas inlet baffle of APH A
(2) Second step: close primary and secondary air outlet
dampers
(3) Third step: shutdown main or auxiliary motor of APH A

8.3 APH and its system operation


8.3.1 Prior to trial operation, check that the following conditions are met:
(1) Both soot blower and flushing pipeline are ready for use immediately.
(2) The preparation of production is ready, complete operators who have been trained and
qualified for the post are deployed
(3) The communication system is reliable and the contact is free.
(4) The covers for trench in MPH are complete, staircase, footpath and safety guards are
proper and all sundries are cleaned completely.
(5) The industrial lighting for equipments and emergency lighting are good and proper and
adequate lighting shall be ensured.
(6) The commissioning for common systems like closed water instrument air and service
air system is completed and can be put into normal operation.
(7) I&C DCS system has the conditions to start and shut down equipment on CRT.
(8) The sundries inside APH and at the trial run site have been cleaned completely.
(9) Confirm that the installation of APHs and their systems are completed and the system is
complete.
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(10 The manhole doors and maintenance hole of APHs have been sealed properly.
(11) The installation lubrication system of guidance and thrust bearing of APHs has been
completed and has charged with oil of stipulated quality and up to normal oil level. The
trial run of the oil pump is qualified and the normal oil circulation and cooling water
circulation has been established.
(12) The oil level in redactor is normal.
(13) The hydro test for oil cooler in oil station system of APHs is qualified and the system
has the conditions for putting into service.
(14) The drive test for interlock protection concerning the oil station of APHs is qualified.
(15) Adjustment of protection and alarm setting has been completed.
(16) Electrical test and interlock test have been completed.
(17) The single trial run of APHs and their motors has been completed.
(18) Manual rotating PH and its rotor has been normal and the cold commissioning of air
leakage control device has been completed.
(19) The check and drive of related flue gas baffle has been completed and normal in
service.
(20) Reliable operation and power supply is available.
(21) Connection of motor is proper and insulation shall be qualified.
(22) The installation calibration of I&C and electrical instrument related to trial run have
been completed and can be put into service.
(23) The installation and commissioning of fire alarming device and shutdown alarm device
of APH have been completed and the devices are normal in service.
8.3.2 Startup preparation for APHs and their system
(1) Put the instrument air compressors and cooling water system into service.
(2) Turn on power supply of APHs and air source and power for air motor.
(3) The oil level and temperature of APH guidance and thrust bearings are normal.
(4) Oil level in the redactor is normal.
(5) Confirm that the APH startup permissive conditions on DCS are met.
8.3.3 Startup of APH
(1) Start up the motor of APH and shutdown the same when the current drops back. Check
APH for correct rotating direction and whether there is abnormal condition.
(2) If there is no abnormal condition, restart the motor of APH.
(3) Trial run the APHs and their system for 8h and monitor the operation parameters which
shall be in a normal range during the trial run.
8.3.4 System operation in the stage of complete set operation
(1) The complete operation is divided into stages of non-load, with load, full load and 30d
reliable operation to test the reliability of operation of the system under various work
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conditions.
(2) During the process of putting APH and the system into operation and especially when
dynamic adjustment of the system is being carried out, the monitor to all equipments in
the system shall be enhanced. Timely adjustment shall be done when there is deviation
from normal operation to ensure that the system is in the best operation state. The
parameters of temperature of all bearings, motor current, outlet and inlet air pressure,
air temperature and flue gas temperature under different load condition shall be
recorded completely.

9. Safety Measures
9.1 Safety Rules for Commissioning
9.1.1 The parties participating in the commissioning will be ware of and observe relevant safety
regulations on the site, wear proper clothes and personal safety protection articles.
9.1.2 In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Then investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning shall obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.2 Personal Risk and Preventative Measures
9.2.1 Injuries might be caused by rotating equipment during commissioning or test. Therefore,
special care must be taken during work and do not touch the rotating components with tools
or your hand。
9.3 Equipment Risk and Preventative Measures
9.3.1 When APHs and their system are started for the first time, people in concerned companies
must be at site the equipment to seriously monitor the equipment. There are reliable
communication measures to contact with CCR.
9.3.2 The soot blowing of APH shall continuously put into service when the oil guns are in service
at the initial stage of boiler lighting up. The discontinuous soot blowing of APH can be done
when the firing is stable and the oil guns are out of service.
9.3.3 Professionals from all specialties shall be at the post during the whole process of trial run to
ensure safe operation of the equipments.
9.3.4 The person works in commissioning shall give order immediately to stop the operation and
break down the commissioning when the APH in operation knocks seriously the mill, the
swing of motor current is too large and even exceeds the rated current and the operation
parameters are over specification. The commissioning of the equipment cannot continue until
the cause has been analyzed and the problems have been solved.

10. Appendix
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Appendix 1 Commissioning Condition Checklist

No. Items Requirements Result Verified by Remarks


1. Environmental Conditions
(1) Site, road and environment Flat, clear and clean □Yes □No
Platform, ladder, handrail, Complete
(2) □Yes □No
guard plate and scaffold Removed
(3) Illuminating Sufficient □Yes □No
(4) Communication equipment Reliable □Yes □No
Sufficient in quantity and
(5) Fire apparatus □Yes □No
easy for use
2. Mechanical conditions
(1) Erection and insulation All fulfilled □Yes □No
(2) Single equipment trial run Qualified □Yes □No
(3) Thin oil station Commissioning qualified □Yes □No
(4) Oil level in reductor Normal □Yes □No
Industrial cooling water Commissioning completed
(5) □Yes □No
system and can be put into service
(6) Sundries inside Cleaning finished □Yes □No
Trial run of pumps is
(7) Alkali flush system qualified and can be put □Yes □No
into service
plates and denomination
(8) Equipments and valves □Yes □No
correct
(9) Doors of manholes All closed □Yes □No
Conditions of electrical
3.
and I&C
Measurement points and Calibration qualified and
(1) □Yes □No
instruments indication correct
Operation in order status
(2) Thin oil station □Yes □No
indication correct
Clearance adjustment
(3) Commissioning fulfilled □Yes □No
device
(4) fire alarming device Commissioning completed □Yes □No
Commissioning
completed, motion normal
(5) Single valve □Yes □No
and status indication
correct
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interlock protection and


(6) Test eligible □Yes □No
alarming
Test is qualified, idle run
for 2h and operation is
(7) Electrical test of motor □Yes □No
proper and rotating
direction is correct
4. Other conditions
Completed and defect
(1) Inspection of system □Yes □No
rectified
Operators deployed,
(2) Production preparation operation tools ready and □Yes □No
operation log ready
Overhaul tools and
(3) Complete □Yes □No
materials
Commanding organization Established and work
(4) □Yes □No
system division clear
Commissioning materials,
(5) tools, instruments, meters Ready and complete □Yes □No
and record formats
(6) Maintenance personnel Sufficient; training passed □Yes □No
(7) Clarification for methods Fulfilled □Yes □No
Commissioning Contractor: Date: Operation Contractor: Date:
Contractor: Date: Dongfang Electric: Date:
Owner Date:
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Appendix 2 Parameter Record for Trial Run of APH and Its System
Parameter Record Format for Trial Run of APH and Its System

Sr.No. Item Unit Data Remarks


1. Main motor current, APH A A
2. Auxiliary motor current, APH A A
3. Top-end bearing oil temperature, APH A ℃
4. Top-end bearing metal temperature, APH A ℃
5. Bottom-end bearing oil temperature, APH A ℃
6. Bottom-end bearing metal temperature, APH A ℃
7. Main motor current, APH B A
8. Auxiliary motor current, APH B A
9. Top-end bearing oil temperature, APH B ℃
10. Top-end bearing metal temperature, APH B ℃
11. Bottom-end bearing oil temperature, APH B ℃
12. Bottom-end bearing metal temperature, APH B ℃
13. Inlet flue gas pressure, APH A KPa
14. Outlet/inlet flue gas differential pressure, APH A KPa
15. Inlet flue gas temperature, APH A ℃
16. Outlet flue gas temperature, APH A ℃
17. Inlet primary air temperature, APH A ℃
18. Outlet secondary air temperature, APH A ℃
19. Inlet flue gas pressure, APH B KPa
20. Outlet/inlet flue gas differential pressure, APH B KPa
21. Inlet flue gas temperature, APH B ℃
22. Outlet flue gas temperature, APH B ℃
23. Inlet primary air temperature, APH B ℃

24. Inlet secondary air temperature, APH B ℃

25.

Commissioning Contractor: Date: Operation Contractor: Date:


PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Air Preheater System REV A


Commissioning
Procedure SCCTI-TS-GL-CS-012-2009A Page 18 of 20

Contractor: Date: Dongfang Electric: Date:


Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Air Preheater System REV A


Commissioning
Procedure SCCTI-TS-GL-CS-012-2009A Page 19 of 20

Appendix 3 Commissioning Record Format of Dampers of APH System


Commissioning Record Format of Dampers of APH System

Remote operation Time


Local
Time of Time of Date of
KKS Name indication Direction Feedback Result Signature Remarks
opening( closing inspection
correct correct correct open) (close)
APH A OUTLET
X0HLA10AA00
SECONDARY AIR MOTOR
2a
DAMPER 1
APH A OUTLET
X0HLA10AA00
SECONDARY AIR MOTOR
2b
DAMPER 2
X0HFE12AA00 PRIMARY AIR OUTLET
1 DAMPER OF APH A
X0HLA20AA00 APH B SA INLET MOTOR
2a DAMPER 1

X0HLA20AA00 APH B SA INLET MOTOR


2b DAMPER 2
X0HFE22AA00 PRIMARY AIR OUTLET
1 DAMPER OF APH B
X0HNA10AA0 FLUE GAS INLET DAMPER 1
01a OF APH A
X0HNA10AA0 FLUE GAS INLET DAMPER 2
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Air Preheater System REV A


Commissioning
Procedure SCCTI-TS-GL-CS-012-2009A Page 20 of 21

01b OF APH A
X0HNA20AA0 FLUE GAS INLET DAMPER 1
01a OF APH B
X0HNA20AA0 FLUE GAS INLET DAMPER 2
01b OF APH B

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-EB-001

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY

SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DETAIL


Commissioning & Test Institute Project DESIGN STAGE
Approval c
Conditio
n Procedure of Coal Handling System
Review Design
Date DWG No. REV
Scale N/A SCCTI-TS-GL-CS-013-2009A A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 2 of 40

Table of Contents

1. PURPOSE 3

2. SCOPE 3

3. PREPARATION BASIS 3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT 3

5. TOOLS, INSTRUMENT FOR COMMISSIONING 6

6. PREREQUISITE FOR COMMISSIONING 7

7. MEASURES FOR COMMISSIONING ORGANIZATION 7

8. COMMISSIONING PROCEDURE 9

9. SAFETY MEASURES 27

9.1 Safety Rules for Commissioning 27

9.2 Personal Risk and Preventative Measures 27

9.3 Equipment Risk and Preventative Measures 27

10. APPENDIX 27

Appendix 1 Commissioning Condition Check-list 28

Appendix 2 CHP equipment operation record format 29

Appendix 3 Trial Run Record Format of CHP 30

Appendix 4 Coal Handling Baffle Commissioning Record 32

Appendix 5 Check List for Programmed Control Startup and Shutdown and Interlock

for Equipment Flow of CHP 33


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 3 of 40

1. Purpose
1.1 Provide a guideline and set specifications for the commissioning work of system and
equipment so as to guarantee that the system and equipment will be able to put into operation
normally and safely.
1.2 To condition electric and I&C protection, interlock and signal devices and confirm their
proper operation.
1.3 To condition equipment running, verify system performance, and detect and remove any
potential defects.

2. Scope
This procedure is applicable for commissioning of CHP including cold state condition
and rotation, interlock protection test of the baffle and startup and shutdown of CHP.

3. Preparation Basis
3.1 Operation manual of system equipment;
3.2 Flow chart of CHP; and
3.3 Control logic chart of CHP.

4. Brief Description of System and Equipment


The scale of power plant new project is 2×315MW and brown coal is used as fuel. The coal is
transported by marine and the scope of CHP is from the coal unloading device of seagoing
vessels to raw coal hopper of MPH coal bunker, including coal unloading, storage, feeding,
sieve and crushing, magnetic separation, weighting and other BOPs.
4.1 Coal unloading
Two sets of coal unloading facilities for seagoing vessels are provided in CHP of this project.
The upper part of the facility is open arranged, 2 berths are provided, through type of coal
unloading is used and the lower part of the facility is a double belt conveyor.
4.2 Coal storage
One coal yard with stacker reclaimer is provided in the first phase of the system with the total
storage of 22.4×104 tons, which can meet the need of two boilers run with full load for 30
days. One set of DQL1250/1250.40 stacker reclaimer is provided in the coal yard. The coal
can be fed to the system by means of two emergency ground coal hoppers and C-07belt
conveyor when the stacker reclaimer is failed. One set of BG-4 gravity variable coal feeder is
provided for each emergency ground coal hopper.
4.3 Screen and crusher
The crusher house is arranged by misalignment and there are two sets of coal screening and
crushing equipments in the house. Two sets of HCSZ-1000 ring hammer crushers and SBS600
roller screens are used, one set for operation and another for standby or the two sets can
operate at the same time for a short time. The comb vibration screen has a bypass system.
4.4 Belt conveyor system
All the belt conveyor systems, except C-3belt conveyor which enters and leaves the coal yard,
are two-ways, one for operation and another for standby. They also can provide cross
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 4 of 40

operation and meet the need of two ways operating at the same time. Electric two-side plough
tripper is used in belt layer of coal bunker room to distribute coal. 14 sets of belt conveyers
are used in the system with belt width of 1200mm, speed of 3.5m/s and output of 1250t/h.
4.5 Main Equipment Specification
4.5.1 Coal unloading unit

No. Description Model & code Unit Q'ty Remarks

1 ship unload unit Q=1250t/h, Set 2

2 sampler for coal entering BMCⅢ Set 2


the plant

gas bag spray dust Operating pressure


3 suppression unit for coal 1.0~1.2MPa Set 1
unloading Water used15m3/h

4.5.2 Equipments in coal yard

No. Description Model & code Unit Q'ty Rem


arks
DQL1250/1250.40 model stacker reclaimer
1 Stacker reclaimer with 1250t/h output of stacking and 1250t/h Set 1
output of reclaiming and with 40m of
cantilever turn radius
Head expansion unit JS.120/320 mode, 3.2m range, applicable belt
2 of rubber belt width of B=1200mm,V=3.5m/s and with Set 1
machine (two provision of local control casing and program
positions) control casing

hydraulic auto DYL-01-6/17 model with local control casing,


3 tightening unit 5.5kW power of motor in hydraulic pump Set 1
station and allowing local and remote control

4 booster pump Flow Q=100m3/h;head 25m;power 15kW, Set 2


380V

5 Submerge wear Flow Q=15m3/h;head 25m;power 7.5kW, Set 1


dredge pump 380V

cantilever self provided trolley traveling mechanism with


6 electromagnetic program controlled cabinet and applicable for Set 1
separator belt width of B=1200mm

Electric single-side DTII04F11 model, variable chute angle,


7 plough tripper applicable for belt width of B=1200mm, with Set 1
single-side hopper and swing gate

8 bulldozer TY220 model Set 2

power not less than 260hp,3 capacity of


9 excavator hopper not less than 4.3m and 9.2m of Set 1
cantilever
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 5 of 40

4.5.3 Coal screening and crushing equipments

No. Description Model & code Unit Q'ty Rem


arks
HCSZ-1000 model, output Q=1000t/h, with
Ring hammer coal monitor panel for measurement of temperature
1 crusher and vibration and hydraulic startup unit; Set 2
granule of outlet coal≤30mm, power of motor
550kW and 6kV
Capacity 1250t/h with motor and bypass unit,
2 roller screen retarder, control casing, steel hopper and Set 2
elbow guard; granule of inlet coal≤300mm
and granule of outlet coal ≤30mm

3 wear dredge pump Flow Q=15m3/h;head 25m;power 7.5kW, Set 1


380V

4 Buffer air lock 900×900mm, applicable belt width 1200mm Set 4

4.5.4 Belt conveyor system

No. Description Model & code Unit Q'ty Rem


arks
B=1200mm, V=3.5m/s, Q=1250t/h, L=202.87m,
1 C-0Abelt conveyor h=12.115m; motor 185kW, 6kV; rubber belt Set 1
EP200-4 non-flammable belt
B=1200mm, V=3.5m/s, Q=1250t/h, L=202.87m,
2 C-1Abelt conveyor h=12.115m; motor 185kW, 6kV; rubber belt Set 1
EP200-4 non-flammable belt
B=1200mm,V=3.5m/s,Q=1250t/h, L=125.3m,
3 C-2Abelt conveyor h=14.415m; motor 185kW, 6kV; rubber belt Set 1
EP200-4 non-flammable belt
B=1200mm, V=3.5m/s, Q=1250t/h, L=
4 C-3belt conveyor 350.90m,h=12m; motor 250kW, 6kV; rubber belt Set 1
ST800 non-flammable belt
B=1200mm, V=3.5m/s, Q=1250t/h,
5 C-4A/B belt LA=90.6m,LB=84.6m, h=21.415m; motor Set 2
conveyor 200kW, 6kV; rubber belt EP200-4 non-flammable
belt

C-5A/B belt B=1200mm, V=3.5m/s, Q=1250t/h,


6 conveyor LA=LB=196.8m,h=46.215m; motor 400kW, Set 2
6kV。EP300-5 non-flammable belt

C-6A/B belt B=1400mm, V=2.5m/s, Q=1250t/h,


7 conveyor LA=LB=138.85m, h=0m; motor 110kW, 0.38kV; Set 2
rubber belt ST630 non-flammable belt
B=1200mm, V=3.5m/s, Q=1250t/h, L=81.7m,
8 C-7belt conveyor h=14m; motor 160kW, 6kV; rubber belt ST630 Set 1
non-flammable belt
mechanical coal CCYZ-12 model, applicable belt width 1200mm,
9 sampler installed total power 30kw Set 3
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 6 of 40

ICS-17A-1200 model, applicable belt width


1200mm, 35° of pulley chute angle, with wall
10 electronic belt hanging indicator & weights-hoist calibration unit, Set 3
weighing unit accumulated allowance ≤±0.5%, calibration
accuracy ±0.25%, operation accuracy ±0.5% and
range of weighing 50~1250t/h

Electric two-side DTII04F11 model, variable chute angle,


11 plough tripper applicable for belt width of B1400mm, with a Set 18
hopper and swing gate
cantilever B=1200mm self provided trolley traveling
12 electromagnetic mechanism with program controlled cabinet and Set 4
separator applicable for belt width of B=1200mm

Disc electromagnetic RCDB-12 model, self provided trolley traveling


13 separator mechanism with program controlled cabinet and Set 2
applicable for belt width of B=1200mm
electric baffle three 900×900mm,60° with electric push lever and
14 way pipe applicable for belt width of 1200mm Set 4

15 Submerge wear Flow Q = 15m3/h ; head 25m ; power 7.5kW, Set 6


dredge pump 380V

16 vibration coal feeder Rated capacity 500t/h Set 2

Hydraulic auto DYL-04-1/10model, model with local control


17 tightening unit casing, 4kW power of motor in hydraulic pump Set 2
station and allowing local and remote control

4.5.5 Control System

Rem
No. Description Model & codec Unit Q'ty
arks
1 Speed monitor JSBHDJ-II model Set 10
2 two-step off tracking switch KPP-12-30 model Set 21
two-direction string-pulling
3 KLS-III model Set 50
switch
4 high charge level meter L2000C model Set 20
5 low charge level meter L2000C model Set 10
6 ultra wave level meter XPL model Set 10
close preventative vibration JZF-6 model trigger vibration
7 Set 10
unit power 250kg and power of 0.4kW
8 coal blocking detector LDB-X model Set 10
9 metal detector Applicable belt width1200mm Set 2

5. Tools, Instrument for Commissioning


5.1 Walkie talkie;
5.2 Handheld vibration meter;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 7 of 40

5.3 c Digital multimeter;


5.4 Handheld thermodetector;
5.5 Tachometer.

6. Prerequisite for Commissioning


Before formally beginning system commissioning, commissioning persons should conduct
comprehensive conditions on conditions that should be available for commissioning of this
system according to contents listed in Appendix 1 (Commissioning condition list) and make
well the records.
6.1 Installation of the system is completed with complete record.
6.2 The inside of system and equipments is cleaned and it is ensured that there is no foreign
matter.
6.3 The marks of equipments are completed and correct.
6.4 Site work condition shall be that the access is free, illumination enough and emergency
lighting available.
6.5 The communication equipments are available.
6.6 The fire fighting materials are enough and easy to get and use.
6.7 The maintenance tools and materials are completed and enough.
6.8 The operation tools and record formats are ready.
6.9 The commissioning tools, instruments and equipments are ready.
6.10 The commissioning of cooling water system is satisfactory and can be put into operation.
6.11 The oil quality of hydraulic oil system is qualified and operation of oil pump is normal.
6.12 Single equipment commissioning in the system is qualified and action reliable.
6.13 The tests for all protection interlock and signal units are qualified.
6.14 Power supply for equipments is reliable.
6.15 All meters and indicators in the system are complete and calibration is qualified.
6.16 Electrical test for motors is satisfactory and running idle for 2h with good condition.

7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows::
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;

◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 8 of 40

◆ Hold technical disclosure meeting for commissioning;

◆ Organize the commissioning work to be carried out by various parties;

◆ Give instructions to operators in the operation;

◆ Prepare commissioning report.


7.2 Responsibilities of Installation Contractor
◆ be responsible for individual commissioning of equipment and provide relevant record
and certificate of commissioning;

◆ be responsible for inspection, maintenance and defect elimination of equipment under


commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;

◆ be responsible for temporary coordination of local control and instruments, terminals.


7.3 Responsibilities of Equipment Manufacturers

◆ Representative of manufacturer, if present on the site offering service, shall provide


technical assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator

◆ Prepare tools to be involved in operation;

◆ Prepare operation log and forms;

◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;

◆ be responsible for patrol inspection, condition and normal maintenance of system and
equipment;

◆ be responsible for dealing with the accidents occurred in commissioning。


7.5 Responsibilities of Dongfang Electric

◆ be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning;

◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning.


7.6 Responsibilities of Owner
◆ Supervise the execution of commissioning procedures;

◆ Witness the commissioning work;

◆ Accept the results of commissioning.


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 9 of 40

8. Commissioning Procedure
8.1 Check and accept the electric three-way baffle and keep the following data:
Condition if KKS code, designation and local position indication is correct, if the remote
operation direction and dback is satisfactory, valve open (close) time, test date and signature
by person in charge of test. Refer to Appendix 4 for detail.
8.2 Interlock Protection and Alarms Condition (Note: the result of logic discussion will prevail for
the item of interlock protection tests);
8.2.1 Place the equipment power supply to test position;
8.2.2 Check the items below:
8.2.2.1 Startup equipment from a computer and feedback on the computer is correct;
8.2.2.2 Shutdown equipment from a computer and feedback on the computer is correct;
8.2.3 Test for single unit local control and emergency buttons.
Check all sections of the belt and CHP equipments and start a single equipment by means of
local control or manual unlock (a way for test the equipment) when condition is provided and
stop the equipment immediately by emergency button or emergency shutdown string-pulling
switch to check for correct rotation direction and good condition of emergency button.
8.2.4 Test for interlock protection of the equipment (Note: the result of logic discussion will prevail
for the item of interlock protection tests)
8.2.4.1 Belt conveyor and accessory equipment
(1) Belt Conveyor A (B), check for condition of start and trip

No. Test item Fixed value Results Remarks


C-0Abelt conveyor startup condition
(1) At remote location
(2) No belt conveyor integrated failure signal
(3) flow selection C-1Abelt conveyor already in operation
Tripping alarm condition for C-0A belt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
(7) flow selection C-1Abelt conveyor operation shutdown
C-1Abelt conveyor startup condition
(1) At remote location
(2) No belt conveyor integrated failure signal
(3) flow selection C-2Abelt conveyor already in
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 10 of 40

operation
Tripping alarm condition for C-1A belt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
(7) flow selection C-2Abelt conveyor operation
shutdown
C-2A belt conveyor startup condition
(1) At remote location
(2) No belt conveyor integrated failure signal
(3) flow selection C-3belt conveyor in operation
Tripping alarm condition for C-2Abelt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
(7) flow selection C-3belt conveyor after operation,
operation shutdown
C-3belt conveyor startup condition
(1) At remote location
(2) No belt conveyor integrated failure signal
(3) Flow from dock to #1 coal yard, 1#stacker reclaimer
(stacking) already in operation;flow from #1 coal
yard to coal bunker, C-4Abelt conveyor already in
operation or C-4Bbelt conveyor already in
operation;flow from dock to coal bunker, C-4Abelt
conveyor already in operation or C-4Bbelt conveyor
already in operation;(or)
Tripping alarm condition for C-3belt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 11 of 40

(6) high temperature of A phase coil of motor (one of any


eight points)
(7) Flow from dock to #1 coal yard, 1# stacker reclaimer
(stacking) operation shutdown;flow from #1coal
yard to coal bunker, C-4Abelt conveyor operation
shutdown or C-4Bbelt conveyor operation
shutdown;flow from dock to coal bunker, C-4 Abelt
conveyor shutdown or C-4B belt conveyor
shutdown ;
C-7belt conveyor startup condition
(1) At remote location
(2) No belt conveyor integrated failure signal
(3) Flow from emergency ground hopper to
bunker ,C-4Abelt conveyor already in operation
Tripping alarm condition for C-7belt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
(7) Flow from emergency ground hopper to bunker,
C-4Abelt conveyor operation shutdown
C-4Abelt conveyor startup condition
(1) At remote location
(2) No belt conveyor integrated failure signal
(3) C-5Abelt conveyor in operation
Tripping alarm condition for C-4Abelt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
(7) roller screen A operation shutdown
(8) C-5Abelt conveyor operation shutdown
C-4Bbelt conveyor startup condition
(1) At remote location
(2) No belt conveyor integrated failure signal
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 12 of 40

(3) C-5Bbelt conveyor in operation


C-4Bbelt conveyor tripping at cantilever condition
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
(7) roller screen B operation shutdown
(8) C-5Bbelt conveyor operation shutdown
C-5Abelt conveyor startup condition
(1) At remote location
(2) No integrated failure signal
(3) C-6Abelt conveyor in operation or C-6Bbelt conveyor
in operation
Tripping alarm condition for C-5Abelt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
(7) C-6A belt conveyor operation shutdown or C-6B belt
conveyor operation shutdown
C-5Bbelt conveyor startup condition
(1) At remote location
(2) No integrated failure signal
(3) C-6B belt conveyor in operation or C-6A belt
conveyor in operation
Tripping alarm condition for C-5Bbelt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 13 of 40

(7) startup selection C-6B belt conveyor after operation


shutdown
(8) flow selection C-6A belt conveyor after operation
shutdown
C-6A belt conveyor startup condition
(1) At remote location
(2) No integrated failure signal
Tripping alarm condition for C-6Abelt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
C-6Bbelt conveyor startup condition
(1) At remote location
(2) No integrated failure signal
Tripping alarm condition for C-6Bbelt conveyor
(1) over current protection action of electrical
(2) 20s delay for skid
(3) 5s delay for off tracking
(4) 12s delay for coal blocking
(5) string-pulling witch action
(6) high temperature of A phase coil of motor (one of any
eight points)
ship unloading machine A startup condition
(1) At remote location
(2) No integrated failure signal
(3) C-1Abelt conveyor in operation
Tripping alarm condition for ship unloading machine A
(1) electrical protection action
(2) C-0Abelt conveyor operation shutdown
ship unloading machine B startup condition
(1) At remote location
(2) No integrated failure signal
(3) C-0Abelt conveyor in operation
Tripping alarm condition for ship unloading machine B
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 14 of 40

(1) electrical protection action


(2) C-0Abelt conveyor operation shutdown

(2) Check for interlock shutdown condition of accessory equipment of belt conveyor

No. Test item Fixed value Results Remarks


TT-0 belt electromagnetic separator A interlock startup condition
(1) C-0A belt conveyor in operation
TT-0 belt electromagnetic separator A interlock shutdown condition
(1) C-0A belt conveyor shutdown
TT-0 impulsive bag dust separator A interlock startup condition
(1) C-0Abelt conveyor in operation
TT-0 impulsive bag dust separator A interlock shutdown
(1) C-0Abelt conveyor shutdown
TT-0 spray dust suppression unit A interlock startup condition
(1) C-0Abelt conveyor in operation
TT-0 spray dust suppression unit A interlock shutdown
(1) C-0A belt conveyor shutdown
C-0A Belt A side vibration close protection unit A interlock startup condition
(1) C-0A belt conveyor in operation and C-1A belt
conveyor in operation
(2) Coal block up
C-0A Belt A side vibration close protection unit A interlock shutdown condition
(1) C-0A belt conveyor operation shutdown and
C-1A belt conveyor operation shutdown delay for 2s
TT-1 belt electromagnetic separator A interlock startup condition
(1) C-1Abelt conveyor in operation
TT-1 belt electromagnetic separator A interlock shutdown condition
(1) C-1Abelt conveyor shutdown
TT-1 belt electromagnetic separator B interlock startup condition
(1) C-1Bbelt conveyor in operation
TT-1 belt electromagnetic separator B interlock shutdown conditon
(1) C-1Bbelt conveyor shutdown
TT-1 impulsive bag dust separator A interlock startup condition
(1) C-1Abelt conveyor in operation
TT-1 impulsive bag dust separator A interlock shutdown condition
(1) C-1A belt conveyor shutdown
TT-1 spray dust suppression unit A interlock startup condition
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Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 15 of 40

(1) C-1A belt conveyor in operation


TT-1 spray dust suppression unit A interlock shutdown condition
(1) C-1A belt conveyor shutdown
C-1A Belt A side vibration close prevention unit interlock startup condition
(1) C-1A belt conveyor in operation and C-2A belt
conveyor in operation
(2) Coal block up
C-1A Belt A side vibration close prevention unit A interlock shutdown condition
(1) C-1Abelt conveyor operation shutdown and C-2Abelt
conveyor operation shutdown delay for 2s
TT-2 impulsive bag dust separator interlock startup condition
(1) C-2Abelt conveyor in operation
TT-2 impulsive bag dust separator interlock shutdown condition
(1) C-2Abelt conveyor shutdown
TT-2 spray dust suppression unit interlock startup condition
(1) C-2Abelt conveyor in operation
TT-2 spray dust suppression unit A interlock shutdown condition
(1) C-2A belt conveyor shutdown
Sampler for coal entering the plant A interlock startup condition
(1) C-1Abelt conveyor in operation
Sampler for coal entering the plant A interlock shutdown condition
(1) C-1Abelt conveyor operation shutdown delay for 60s
Roller screen A pull lever interlock startup condition
(1) roller screen A operation shutdown
(2) electrical failure
(3) transfer blocking failure
Roller screen A heater interlock startup condition
(1) roller screen A in operation
Roller screen A heater interlock shutdown condition
(1) roller screen A operation shutdown
(2) electrical failure
(3) transfer blocking failure
Roller screen B pull lever interlock startup condition
(1) roller screen B operation shutdown
(2) electrical failure
(3) transfer blocking failure
Roller screen B heater interlock startup condition
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Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 16 of 40

(1) roller screen A in operation


Roller screen B heater interlock shutdown condition
(1) roller screen A operation shutdown
(2) electrical failure
(3) transfer blocking failure
Impulsive bag dust separator in coal crusher house A interlock startup condition
(1) C-4A belt conveyor in operation
Impulsive bag dust separator in coal crusher house A interlock shutdown condition
(1) C-4Abelt conveyor shutdown delay for 60s
Impulsive bag dust separator in coal crusher house B interlock startup condition
(1) C-4B belt conveyor in operation
Impulsive bag dust separator in coal crusher house B interlock shutdown condition
(1) C-4B belt conveyor shutdown delay for 60s
Coal crusher house spray dust suppression unit A interlock startup condition
(1) C-5Abelt conveyor in operation
Coal crusher house spray dust suppression unit A interlock shutdown condition
(1) C-5Abelt conveyor shutdown
Coal crusher house spray dust suppression unit B interlock startup condition
(1) C-5B belt conveyor in operation
Coal crusher house spray dust suppression unit B interlock shutdown condition
(1) C-5B belt conveyor shutdown
Coal crusher house outside metal detector A interlock startup condition
(1) C-5Abelt conveyor in operation
Coal crusher house outside metal detector A interlock shutdown condition
(1) C-5Abelt conveyor shutdown delay for 60s
Coal crusher house outside metal detector B interlock startup condition
(1) C-5B belt conveyor in operation
Coal crusher house outside metal detector B interlock shutdown condition
(1) C-5B belt conveyor shutdown delay for 60s
Coal crusher house outside disc electromagnetic separator A interlock startup condition
(1) C-5Abelt conveyor in operation and C-4Abelt
conveyor in operation
Coal crusher house disc electromagnetic separator A interlock shutdown condition
(1) C-5Abelt conveyor shutdown and C-4Abelt
conveyor shutdown
Coal crusher house outside disc electromagnetic separator B interlock startup condition
(1) C-5Bbelt conveyor in operation and C-4Bbelt
conveyor in operation
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Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 17 of 40

Coal crusher house disc electromagnetic separator B interlock shutdown condition


(1) C-5Bbelt conveyor shutdown and C-4Bbelt conveyor
shutdown
Coal crusher house vibration close prevention unit B interlock startup condition
(1) C-5Bbelt conveyor in operation and C-4Bbelt
conveyor in operation
(2) Coal block up
Coal crusher house vibration close prevention unit A interlock startup condition
(1) C-5Abelt conveyor in operation and C-4Abelt
conveyor in operation
(2) Coal block up
Coal crusher house vibration close prevention unit D interlock shutdown condition
(1) C-5A belt conveyor operation shutdown and
C-4A belt conveyor operation shutdown delay for 2s
Coal crusher house vibration close prevention unit B interlock shutdown condition
(1) C-5Bbelt conveyor operation shutdown and
C-4Bbelt conveyor operation shutdown delay for 2s
Coal crusher house vibration close prevention unit C interlock startup condition
(1) C-5Abelt conveyor in operation and C-4Abelt
conveyor in operation
(2) Coal block up
Coal crusher house vibration close prevention unit D interlock shutdown condition
(1) C-5Abelt conveyor operation shutdown and
C-4Abelt conveyor operation shutdown delay for 2s
Coal crusher house vibration close prevention unit D interlock startup condition
(1) C-5Bbelt conveyor in operation and C-4Bbelt
conveyor in operation
(2) Coal block up
Coal crusher house vibration close prevention unit D interlock shutdown condition
(1) C-5B belt conveyor operation shutdown and
C-4B belt conveyor operation shutdown delay for 2s
C-5A Belt electromagnetic separator
(1) C-5Abelt conveyor in operation, interlock startup belt
electromagnetic separator
(2) C-5Abelt conveyor operation shutdown, interlock
shutdown belt electromagnetic separator
Sampler for coal as fired A interlock startup condition
(1) C-5Abelt conveyor in operation
Sampler for coal as fired A interlock shutdown
(1) C-5Abelt conveyor operation shutdown delay
for 60S
Sampler for coal as fired B interlock startup condition
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Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 18 of 40

(1) C-5Bbelt conveyor in operation


Sampler for coal as fired B interlock shutdown
(1) C-5B belt conveyor operation shutdown delay
for 60S
C-5A Belt A side vibration close prevention unit interlock startup condition
(1) C-5A belt conveyor in operation and C-6Abelt
conveyor in operation
(2) Coal block up
C-5A Belt A side vibration close prevention unit interlock shutdown condition
(1) C-5Abelt conveyor operation shutdown and
C-6Abelt conveyor operation shutdown delay
for 2s
C-5A Belt B side vibration close prevention unit interlock startup condition
(1) C-5Abelt conveyor in operation and C-6Bbelt
conveyor in operation
(2) Coal block up
C-5A Belt B side vibration close prevention unit interlock shutdown condition
(1) C-5Abelt conveyor operation shutdown and
C-6Bbelt conveyor operation shutdown delay for
2s
C-5BBelt A side vibration close prevention unit interlock startup condition
(1) C-5Bbelt conveyor in operation and C-6Abelt
conveyor in operation
(2) Coal block up
C-5B Belt A side vibration close prevention unit interlock shutdown condition
(1) C-5Bbelt conveyor operation shutdown and
C-6Abelt conveyor operation shutdown delay
for 2s
C-5B Belt B side vibration close prevention unit interlock startup condition
(1) C-5Bbelt conveyor in operation and C-6Bbelt
conveyor in operation
(2) Coal block up
C-5B Belt B side vibration close prevention unit interlock shutdown condition
(1) C-5Bbelt conveyor operation shutdown and
C-6Bbelt conveyor operation shutdown delay
for 2s
TT-3 belt electromagnetic separator A interlock startup condition
(1) C-3belt conveyor in operation and C-4Abelt
conveyor in operation
TT-3 belt electromagnetic separator A interlock shutdown condition
(1) C-3belt conveyor shutdown and C-4Abelt conveyor
shutdown
TT-3 impulsive bag dust separator A interlock startup condition
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Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 19 of 40

(1) C-3belt conveyor in operation


TT-3 impulsive bag dust separator A interlock shutdown condition
(1) C-3 belt conveyor shutdown
TT-3 impulsive bag dust separator B interlock startup condition
(1) C-3 belt conveyor in operation
TT-3 impulsive bag dust separator B interlock shutdown condition
(1) C-3 belt conveyor shutdown
TT-3 spray dust suppression unit A interlock startup condition
(1) C-3belt conveyor in operation
TT-3 spray dust suppression unit A interlock shutdown condition
(1) C-3belt conveyor shutdown
TT-3 spray dust suppression unit B interlock startup condition
(1) C-3belt conveyor in operation
TT-3 spray dust suppression unit B interlock shutdown condition
(1) C-3belt conveyor shutdown
Coal bunker room TT belt electromagnetic separator A interlock startup condition
(1) C-5A belt conveyor in operation
Coal bunker room TT belt electromagnetic separator A interlock shutdown condition
(1) C-5A belt conveyor shutdown
Coal bunker room TT belt electromagnetic separator B interlock startup condition
(1) C-5B belt conveyor in operation
Coal bunker room TT belt electromagnetic separator B interlock shutdown condition
(1) C-5B belt conveyor shutdown
Coal bunker room TT impulsive bag dust separator A interlock startup condition
(1) C-5A belt conveyor in operation
Coal bunker room TT impulsive bag dust separator A interlock shutdown condition
(1) C-5Abelt conveyor shutdown
Coal bunker room TT impulsive bag dust separator B interlock startup condition
(1) C-5Bbelt conveyor in operation
Coal bunker room TT Impulsive bag dust separator B interlock shutdown condition
(1) C-5Bbelt conveyor shutdown
Coal bunker room TT Spray dust suppression unit A interlock startup condition
(1) C-6Abelt conveyor in operation
Coal bunker room TT Spray dust suppression unit A interlock shutdown condition
(1) C-6Abelt conveyor shutdown
Coal bunker room TT Spray dust suppression unit B interlock startup condition
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Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 20 of 40

(1) C-6Bbelt conveyor in operation


Coal bunker room TT Spray dust suppression unit B interlock shutdown condition
(1) C-6Bbelt conveyor shutdown

(3) Roller screen A(B) startup tripping condition check

No. Test item Fixed value Results Remarks


roller screen A startup condition
(1) At remote location c
(2) No integrated failure signal
(3) C-5Abelt conveyor in operation and C-4Abelt
conveyor in operation
roller screen A tripping alarm condition
(1) electrical failure
(2) transfer blocking failure
(3) Action of emergency button
(4) C-5Abelt conveyor operation shutdown and
C-4Abelt conveyor operation shutdown delay
for 2s
roller screen B startup condition
(1) At remote location
(2) No integrated failure signal
(3) C-5Bbelt conveyor in operation and C-4Bbelt
conveyor in operation
roller screen B tripping alarm condition
(1) electrical failure
(2) transfer blocking failure
(3) Action of emergency button
(4) C-5Bbelt conveyor operation shutdown and
C-4Bbelt conveyor operation shutdown delay
for 2s

(4) ring hammer coal crusher A(B) startup tripping condition check

No. Test item Fixed value Results Remarks


ring hammer coal crusher A startup condition
(1) At remote location c
(2) No integrated failure signal
(3) C-5Abelt conveyor in operation and C-4Abelt
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Commissioning
Procedure
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conveyor in operation
ring hammer coal crusher A tripping alarm condition
(1) electrical protection action
(2) high vibration in left bearing, alarm delay for 3s
(3) high vibration in right bearing, alarm delay for 3s
(4) high temperature in left bearing, alarm delay for 3s
(5) high temperature in right bearing, alarm delay for 3s
(6) Action of emergency button
(7) C-5Abelt conveyor in operation and C-4Abelt
conveyor shutdown
ring hammer coal crusher B startup condition
(1) At remote location
(2) No integrated failure signal
(3) C-5Bbelt conveyor in operation and C-4Bbelt
conveyor in operation
ring hammer coal crusher B tripping alarm condition
(1) electrical protection action
(2) high vibration in left bearing, alarm delay for 3s
(3) high vibration in right bearing, alarm delay for 3s
(4) high temperature in left bearing, alarm delay for 3s
(5) high temperature in right bearing, alarm delay for 3s
(6) Action of emergency button
(7) C-5Bbelt conveyor in operation and C-4Bbelt
conveyor shutdown

(5) stacker reclaimer startup tripping condition check

No. Test item Fixed value Results Remarks


stacker reclaimer startup condition
(1) At remote location c
(2) No integrated failure signal
(3) C-3belt conveyor in operation when reclaiming coal
or request stacker reclaimer in operation when
stacking coal
stacker reclaimer tripping alarm condition
(1) electrical protection action
(2) C-3belt conveyor operation shutdown when
reclaiming coal or request stacker reclaimer in
shutdown condition when stacking coal
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Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 22 of 40

(6) Vibration coal feeder A (B) startup tripping condition check

No. Test item Fixed value Results Remarks


Vibration coal feeder A startup condition
(1) Programmed control allowed for coal feeder
(2) No electrical failure
(3) C-7belt conveyor in operation
Vibration coal feeder A tripping alarm condition
(1) electrical failure
(2) C-7belt conveyor operation shutdown
Vibration coal feeder B startup condition
(1) Programmed control allowed for coal feeder
(2) No electrical failure
(3) C-7belt conveyor in operation
Vibration coal feeder B tripping alarm condition
(1) electrical failure
(2) C-7belt conveyor operation shutdown

8.2.5 CHP interlock


8.2.5.1 If the upstream equipment, reverse coal flow of this equipment, startup is done, the system
will startup automatically when the system is in auto.
8.2.5.2 The equipment will be shut down immediately and equipments in the emergency flow of the
system also will be shut down immediately (except the crusher and screen will delay fro 5s) if
this equipment is failed or a downstream equipment, in the same direction as of coal flow of
this equipment, is failed.
8.2.5.3 The three-way baffle expansion head will in operation after the operator gives order of
pre-startup order of the flow after the operation has made the flow selection.
8.2.5.4 The electric three-way baffle and the belt conveyor expansion heads can only switch the unit
position in the state of belt conveyor shutdown and belt conveyor interlocked with the
upstream belt conveyor.
8.2.5.5 The magnetic separator will start up with the corresponding belt conveyor at the same time
but delay in shutdown.
8.2.5.6 The magnetic separator will start up with the corresponding belt conveyor in interlock and the
startup will be in advance and delay in shutdown.
8.2.5.7 The lifting up and lowering down of the plough tripper is interlocked with coal level of coal
bunker, the plough tripper in maintenance bunker and full level coal bunker is kept lifting up
and the plough tripper in the rear bunker is kept lowering down.
8.2.5.8 The stacker reclaimer is interlocked with C-3belt conveyor (under the precondition of having
person signal of stacking or reclaiming operation)
8.2.6 Test for system interlock
8.2.6.1 Startup interlock: In case of starting up the system, the startup begins in sequence from the
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Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 23 of 40

last belt conveyor to the first belt conveyor, in the refluent direction of coal flow and then start
to feed coal.
8.2.6.2 Shutdown interlock: When the operation requires to shutdown, the coal supply shall stopped
first. And then shutdown the conveyor from first to last in the same direction as coal flow.
Each belt conveyor will be delayed to shutdown as per set time between them, i.e. it is
required that the remained coal on the front belt conveyor finished and the stop its operation.

8.2.6.3 Emergency interlock:

‹ In operation, if there is a grave accident in any of equipments, the equipment refluent to


the coal flow will trip in interlock immediately, except the crusher which will trip in
delay if it is not an accident of the crusher.

‹ When the emergency shutdown button is pressed, the equipments in operation will
shutdown totally, except the crusher and screen which will be shutdown in delay.
8.2.6.4 Use of interlock:

‹ The action of interlock is allowed by means of the signal sent by relay in the interlock
loop. Therefore, in any of operation ways, the interlock position shall be correctly put in
service for all operation equipments, otherwise, the interlock will not act.

‹ The in-service position of all interlock switch shall be consistent with the operation way
of the system.

‹ When single equipment is trial run, the interlock of the equipment is released.
8.2.6.5 For tests of actual program control startup and shutdown and system interlock, refer to
Appendix 5.
8.3 CHP startup and shutdown
8.3.1 Check before startup
8.3.1.1 Ground of coal storage yard shall be level, drain free and illumination enough.
8.3.1.2 The installation of stacker reclaimer shall be as per requirement of construction and
acceptance regulations. The requirements include the following, but not limited to:

◆ The lead sealing of hydraulic pressure equipments and elements shall be complete and
no damage; the lubricant and hydraulic system are cleaned, pressure test qualified and
all the hydraulic pressure equipments and elements shall work normally without leakage
during trial run.

◆ The pitching hydraulic oil cylinders on both sides of the gate column shall be parallel
and vertical to the horizontal level. The rise and fall of the two hydraulic cylinder piston
link shall be synchronized and the level of rise and fall consistent.

◆ Check for that the speed of bucket wheel conforms to the regulation, belt working
normal without skid or off tracking and the feed belt coal chute shall be at the same
concentricity with the rotor plate. The contact of all wheels with rail shall be proper,
work of the rail clamping device normal and reading of indicator correct.
8.3.1.3 The installation of coal unloading trench, ground coal bunker and rail shall meet the
requirement of the acceptant regulations and the illumination inside shall be enough and
explosive proof type.
8.3.1.4 The work of coal unloading spray dust suppression device is normal.
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Commissioning
Procedure
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8.3.1.5 The installation of all coal handling belt of coal conveyors is completed and conforms to the
construction acceptant regulations, include but not limited to the following requirements:

◆ There shall be no hardening, chapping, wearing or friction on the rubber surface of the
belt. The operation shall be smooth and the off tracking shall not be beyond the edge of
the pulley.
◆ The connection between the pulley support and frame shall be fast, the bearing of pulley
shall insert the groove of support fast and the surface of pulley smooth and without burr.
The lubrication of the pulley is normal and rotation free.
◆ The axial line of pulley must be vertical to the belt. The elevation of all frame and
non-smooth shall conform to the regulations.
◆ The fastening device at the rear shall be free, the sliding surface and rod shall be straight
and well lubricated. The vertical fastening device is parallel with the slide way, rise and
fall free and there shall be protection guard plate at the turning of the belt to prevent
metal material from falling in.
◆ The placement of balance block shall be reliable. The balance shall be proper and when
skids in coal feeding shall increase. The work of tightening device shall be normal when
the belt is started or shut down and the belt will not skid.
◆ The commissioning of belt tightening device and the hydraulic device is completed and
can be put into service.
◆ The commissioning of belt expansion device is completed and can be put into service.

◆ The coal guide chute shall be parallel to the belt, center aligned and the contact at the
seal is smooth.
◆ The interlock with all section emergency buttons is in proper state. The room
illumination is enough, the installation of the ventilation and dust proof unit is
completed. The work of switch coal baffle is free and tight.
8.3.1.6 The installation of the crusher and screen is completed, all parts are fast and reliable, rotation
free, the foundation bolts are connected fast and the idle run is qualified.
8.3.1.7 The installation angel, magnetic surface and distance between the belts of the electromagnetic
separator shall conform to the design and the hanging shall be reliable.
8.3.1.8 The installation of the plough tripper is completed with free operation and correct position of
movement weight.
8.3.1.9 The inside of coal bunker is clean without foreign matters and leakage from anywhere of the
seal.
8.3.1.10 the electronic weighing unit is cleaned without accumulated coal or dust and the calibration is
qualified and it can be put into service.
8.3.1.11 all kinds of instruments in the coal control room shall be completed, light alarm is good and
the illumination and communication equipment are completed and ready.
8.3.2 Tests for system idle startup and interlock
Check for all sections of belt conveyors and coal handling equipments and after the condition
is available, startup all equipments as per sequence by means of program control auto or
manual interlock. After ensuring that the operation is normal, shutdown the rear belt conveyor
or any equipment or belt conveyor in the system, the other upstream equipments or belt
conveyors shall shutdown in sequence and the alarm signal is sent.
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Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 25 of 40

The test for system interlock will be carried out as per five operation modes below and all
equipments will startup as per sequence.

‹ ship unloading machine→coal bunker

‹ ship unloading machine →stacker reclaimer →coal yard

‹ ship unloading machine →emergency→coal yard

‹ stacker reclaimer coal yard——coal bunker


‹ emergency hopper→coal bunker
For detail, refer to Appendix 5
8.3.3 Check for iron attraction of the electromagnetic separator
After completion of installation and commissioning of the electromagnetic separator, the iron
attraction of the electromagnetic separator can be carried out. In the test, different shape and
weight of iron pieces is placed on the belt and then put the electromagnetic separator into
service. Observe the iron attraction and repeat the test many times, record the result and count
the rate of iron attraction. If failure of iron attraction is found, the cause shall be found out. All
the iron pieces on the belt shall be removed after the test is completed.
8.3.4 Test for idle run of CHP and coalfeeding.
Five operation modes of CHP idle operation can be carried out after the check and test of all
kinds of startups are normal. The coalfeeding test can be carried out when the boiler house
raw coal hopper is ready for coalfeeding.
8.3.5 Other auxiliary system and equipments in service
(1) Vibration coal feeder
(2) Electric plough tripper
(3) Mechanical sampler
(4) Dust separator
(5) Electronic belt weighing unit
(6) Sewage purification and flushing water supply equipment
8.3.6 Put the system into operation
8.3.6.1 Programm control auto control means
(1) The selected coalfeeding mode is “Program control” by the control station and press
“reset” to make the program in initial state.
(2) Select flow selection in the control station as per coal flow direction, verify the Flow
valid and the flows are per operation modes:

‹ ship unloading machine→coal bunker


‹ ship unloading machine →stacker reclaimer →coal yard
‹ ship unloading machine →emergency→coal yard
‹ stacker reclaimer →s coal yard——coal bunker
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Commissioning
Procedure
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‹ emergency ground hopper→coal bunker


(3) Press “Pre-startup” button on “the total flow chart” in the control station to check for
correct position of all plough trippers and confirm that the system startup is permitted.
(4) Press “Program startup” to start all equipments in the system as per flow selected.
(5) In the process of program startup, if any equipment is failed the process of program
startup is terminated. After the problem is removed, press “Reset”, “Pre-startup” and
“program startup” buttons, the program startup process will start from the equipment
where the failure occur.
(6) When it is in program control auto shutdown, press “Program shutdown” button and
select coal source and after “Confirmation”, the equipment in operation will
automatically shutdown with delay as per flow direction of coal from the place where
the coal source is.
8.3.6.2 Interlock manual control mode
(1) The “Interlock” of coalfeeding mode is selected in the control station and press “Reset”
and “distribution and reset” buttons to make the program initial state.
(2) Select the flow as per coal flow direction in the control station and confirm that “Flow is
valid”.
(3) Check for correct position of the plough tripper and baffle by manual operation in the
“Total flow chart” at the control station.
(4) Startup all equipments in the Flow at “Inquiry of control and status” window of each
equipment as per refluent coal flow direction.
(5) During startup, if accident occurs, eliminate the failure and then press “Reset” button
and manually initiate startup process at the place where the equipment failed.
(6) In normal shutdown, shutdown in sequence the equipments in the Flow at “Inquiry of
control and status” window of each equipment as per the same direction of coal flow
direction.
8.3.6.3 Mode of coal distribution
(1) Program coal distribution

◆ ”Program coal distribution” is selected in the control station and press


“Distribution reset” button to make the coal distribution program in an initial state.

◆ Press “Pre-startup” button at the control station to check for the fall down position
of the rear plough tripper and the rest in rise up position.

◆ When the belt conveyor is already in operation, the program will start the
automatically coal distribution evenly with the priority as per low coal level to
high coal level and the balance.

◆ The program coal distribution is completed when all coal bunkers have distributed
to high coal level, the system starts to shutdown in delay all equipments as per
coal source sequence.
(2) When it is in manual coal distribution, the selected coal distribution mode is “Manual
distribution” and distributes coal with manual operation of all plough trippers.
8.4 System Operation during Integral Startup
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Procedure
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The reliability of the system operation is tested as per non-load phase, load phase, full load
phase and 30 days relciability operation phase.
(1) Dynamic regulation of system: in the process of system in service and especially
running with load, the monitor of the equipment shall be strengthened to ensure that the
system is in the best state.
(2) Complete trial operation record: for the main parameters in the trial run startup, refer to
Appendix 2 and 3.

9. Safety Measures
9.1 Safety Rules for Commissioning
9.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant
safety rules, wear reasonable clothing and appropriate personal protective equipments.
9.1.2 In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Then investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning shall obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.1.4 All professional shall be on respective duties during the whole commissioning to guarantee
the safe operation of equipments.
9.2 Personal Risk and Preventative Measures
9.2.1 Injuries might be caused by rotating equipment during commissioning or test. Therefore,
special care must be taken during work and do not touch the rotating components with tools
or your hand.
9.2.2 The complete and fast protection railing shall be installed on both sides of belt conveyors.
9.2.3 In the period of commissioning, the ground building ventilation facilities shall be put in
service and the emergency exit free.
9.2.4 During system startup and interlock test, special person shall be deployed to monitor and
check all the equipments and belts. The communication contact shall be kept. Any situation
shall be reported in time and all the operation shall be directed in unification.
9.3 Equipment Risk and Preventative Measures
9.3.1 When the position of head expansion device is switched over, the belt conveyor must be
started up in idle state first and then switch over the position.
9.3.2 The eye striking sign shall be provided at the cross place between the edge of coal yard and
surface place of tunnel to prevent the top of tunnel from damaging by bulldozer.
9.3.3 If any risk situation occurs during the equipment operation, the equipment can be shut down
by “Emergency shutdown” button.
9.3.4 If the stopped flow has common equipments with other flow, the mode of “Program shutdown
cannot be used. The mode of manual interlock is used to shutdown in sequence the equipment
to the place where it is across with other flow.

10. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 28 of 40

Appendix 1 Commissioning Condition Check-list

No. Items Requirements Result Remarks

1 System installation installation completed with complete □Yes □No


record

2 Inside system and Cleaned and no foreign matters □Yes □No


equipment
3 Equipment markings Marking complete and correct □Yes □No

4 Field condition Access free, illumination enough and □Yes □No


emergency illumination available

5 Communication available □Yes □No


equipment

6 Fire apparatus Sufficient in quantity and easy for □Yes □No


use

7 Overhaul tools and Complete and enough □Yes □No


materials

8 operation tools and Prepared □Yes □No


record formats

9 Commissioning tools Prepared □Yes □No


and instruments

10 Cooling water commissioning satisfactory and can □Yes □No


system be put into operation

11 Hydraulic oil system Oil quality qualified and oil pump □Yes □No
operation normal

12 Equipments in Single equipment commissioning □Yes □No


system satisfactory and action reliable
All protection
13 interlock and signal Test eligible □Yes □No
unit
14 Power supply Reliable □Yes □No
All kinds of meters Complete and satisfactory in
15 and gauges in the calibration □Yes □No
system

16 Electrical test of Test is qualified and having 2h idle □Yes □No


motor operation and condition is good.

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 29 of 40

Appendix 2 CHP equipment operation record format

No. Item Unit startup shutdown Remarks


C-0A belt conveyor 00EAC11AF000 A
C-1A belt conveyor 00EAC11AF001 A
C-2A belt conveyor 00EAC11AF002 A
C-3 belt conveyor 00EAC11AF003 A
C-7 belt conveyor 00EAC11AF007 A
C-4A belt conveyor 00EAC11AF004 A
C-4B belt conveyor 00EAC12AF004 A
C-5A belt conveyor 00EAC11AF005 A
C-5BA belt conveyor 00EAC12AF005 A
C-6A belt conveyor 00EAC11AF006 A
C-6B belt conveyor 00EAC12AF006 A
1#stacker reclaimer 00EAF11AF001 A
A ring hammer coal crusher A
00EBC11AJ001
Bring hammer coal crusher A
00EBC12AJ001
A roller screen 00EBD11AT001 A
B roller screen 00EBD12AT001 A
17 Vibration coal feeder 00EAB11AF001 A
18 Vibration coal feeder 00EAB11AF002 A

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 30 of 40

Appendix 3 Trial Run Record Format of CHP

No. Items Operation Problems


1 C-0Abelt conveyor 00EAC11AF000
2 C-1Abelt conveyor 00EAC11AF001
3 C-2Abelt conveyor 00EAC11AF002
4 C-3belt conveyor 00EAC11AF003
5 C-7belt conveyor 00EAC11AF007
6 C-4Abelt conveyor 00EAC11AF004
7 C-4Bbelt conveyor 00EAC12AF004
8 C-5Abelt conveyor 00EAC11AF005
9 C-5BAbelt conveyor00EAC12AF005
10 C-6Abelt conveyor 00EAC11AF006
11 C-6Bbelt conveyor 00EAC12AF006
12 1#stacker reclaimer 00EAF11AF001
13 Belt electromagnetic separator 00EBE11AT101
14 Belt electromagnetic separator 00EBE11AT301
15 Belt electromagnetic separator 00EBE11AT701
16 Belt electromagnetic separator 00EBE11AT501
17 Belt electromagnetic separator 00EBE12AT501
18 Disc electromagnetic separator 00EBE11AT401
19 Disc electromagnetic separator 00EBE12AT401
20 metal detector 00EBE11AT402
21 metal detector 00EBE12AT402
22 A ring hammer coal crusher 00EBC11AJ001
23 B ring hammer coal crusher 00EBC12AJ001
24 A roller screen 00EBD11AT001
25 B roller screen 00EBD12AT001
26 A rain scraper 00EAF11AB001
27 Electric two-side plough tripper 00EAC11AF601
28 Electric two-side plough tripper 00EAC11AF602
29 Electric two-side plough tripper 00EAC11AF603
30 Electric two-side plough tripper 00EAC11AF604
31 Electric two-side plough tripper 00EAC11AF605
32 Electric two-side plough tripper 00EAC11AF606
33 Electric two-side plough tripper 00EAC11AF607
34 Electric two-side plough tripper 00EAC11AF608
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Coal Handling System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-013-2009A Page 31 of 40

35 Electric two-side plough tripper 00EAC11AF609


36 Electric two-side plough tripper 00EAC12AF601
37 Electric two-side plough tripper 00EAC12AF602
38 Electric two-side plough tripper 00EAC12AF603
39 Electric two-side plough tripper00EAC12AF604
40 Electric two-side plough tripper 00EAC12AF605
41 Electric two-side plough tripper 00EAC12AF606
42 Electric two-side plough tripper 00EAC12AF607
43 Electric two-side plough tripper 00EAC12AF608
44 Electric two-side plough tripper 00EAC12AF609
45 Electric single-side plough tripper 00EAC11AF201
46 Reciprocating coal feeder 00EAB11AF001
47 Reciprocating coal feeder 00EAB11AF002
48 mechanical sampler for coal as received
00EAU11AE101
49 mechanical sampler for coal as fired
00EBU11AE501
50 mechanical sampler for coal as fired
00EBU12AE501
51 Electronic belt weighing unit 00EAT11AF101
52 TT-1Impulsive bag dust separator02EBP30AZ001
53 TT-2Impulsive bag dust separator03EBP30AZ001
54 1#TT spray dust suppression unit 02EBP30AZ002
55 2#TT spray dust suppression unit 03EBP30AZ002

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Coal Handling System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-013-2009A Page 32 of 40

Appendix 4 Coal Handling Baffle Commissioning Record


Baffle Commissioning Record

Remote Operating time


KKS code Name Local position Feedbac Date Result Signatu Remark
indication Directio k Opening Closing re s
n correct time time
correct
00EAC11AA001 electric baffle three-way pipe
00EAC11AA101 electric baffle three-way pipe
00EAC11AA501 electric baffle three-way pipe
00EAC12AA501 electric baffle three-way pipe
00EBD11AT001 A roller screen handspike
00EBD12AT001 B roller screen handspike

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Coal Handling System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-013-2009A Page 33 of 40

Appendix 5 Check List for Programmed Control Startup and Shutdown and Interlock for Equipment Flow of CHP

No. Inspection contents Result Signature


1.Dock→#1 coal yard
Flow 1: ship unloading machine (1# or 2#) →electric three-way pass A side→C-1A belt conveyor (Belt electromagnetic separator) →electric three-way pass A
side→C-2A belt conveyor→C-3 belt conveyor→1# stacker reclaimer→#1 coal yard

01 Program control startup (the downstream equipment startup first and continue to the last
equipment)

02 Program controlled shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
2.Dock→coal bunker
Flow2: ship unloading machine (1# or 2#) →electric three-way pass A side→C-1A belt conveyor (Belt electromagnetic separator) →electric three-way pass A
side→C-2 Abelt conveyor→C-3 belt conveyor→C-4Abelt conveyor (Disc electromagnetic separator) →A roller screen →A ring hammer coal crusher→C-5Abelt
conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue to
shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments


PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Coal Handling System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-013-2009A Page 34 of 40

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
Flow3: ship unloading machine (1# or 2#) →electric three-way pass A side→C-1A belt conveyor(Belt electromagnetic separator) →electric three-way pass A
side→C-2A belt conveyor→C-3 belt conveyor→C-4A belt conveyor(Disc electromagnetic separator) →A roller screen →A ring hammer coal crusher→C-5Abelt
conveyor(Belt electromagnetic separator) →electric three-way pass Bside→C-6A belt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue to
shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
Flow4: ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A
side→C-2Abelt conveyor→C-3belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →bypass A→C-5Abelt conveyor(Belt electromagnetic
separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue to
shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Coal Handling System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-013-2009A Page 35 of 40

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s)
Flow5: ship unloading machine (#1 or #2 )→electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A
side→C-2A belt conveyor→C-3belt conveyor→C-4A belt conveyor(Disc electromagnetic separator) →bypass A→C-5A belt conveyor(Belt electromagnetic
separator) →electric three-way pass B side→C-6B belt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue to
shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
Flow6: ship unloading machine (#1 or #2 )→electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A
side→C-2Abelt conveyor→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal crusher→C-5Bbelt
conveyor(Belt electromagnetic separator) →electric three-way pass B side→C-6Bbelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue to
shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s)
Flow7: ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A
side→C-2Abelt conveyor→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →bypass B→C-5Bbelt conveyor(Belt electromagnetic
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Coal Handling System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-013-2009A Page 36 of 40

separator) →electric three-way pass B side→C-6Bbelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s)
Flow8: ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A
side→C-2Abelt conveyor→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal crusher→C-5Bbelt
conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
Flow9: ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A
side→C-2Abelt conveyor→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →bypass B→C-5Bbelt conveyor(Belt electromagnetic
separator) →electric three-way pass A side→C-6Abelt conveyor (Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Coal Handling System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-013-2009A Page 37 of 40

02 Program control shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
3.Dock emergency→#1 coal yard
Flow1: ship unloading machine (#1 or #2 ) →electric three-way pass A side→C-1Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A
side→C-2A belt conveyor→#1 coal yard

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
4.#1 coal yard→coal bunker
Flow10:#1 coal yard→#1 stacker reclaimer→C-3belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →A roller screen →A ring hammer coal
crusher→C-5Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Coal Handling System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-013-2009A Page 38 of 40

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
Flow11:#1 coal yard→#1 stacker reclaimer→C-3belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →A roller screen →A ring hammer coal
crusher→C-5Abelt conveyor(Belt electromagnetic separator) →electric three-way pass Bside→C-6Bbelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
Flow12:#1 coal yard→#1 stacker reclaimer→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal
crusher→C-5Bbelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (The upstream equipment shutdown first and continue to
the last equipment )

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Coal Handling System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-013-2009A Page 39 of 40

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
Flow13:#1 coal yard→#1 stacker reclaimer→C-3belt conveyor→C-4Bbelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal
crusher→C-5Bbelt conveyor(Belt electromagnetic separator) →electric three-way pass B side→C-6Bbelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )
5.emergency ground hopper →coal bunker
Flow14:#1 coal yard→emergency hopper→C-07belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →A roller screen →A ring hammer coal
crusher→C-5Abelt conveyor(Belt electromagnetic separator) →electric three-way pass A side→C-6Abelt conveyor(Electric two-side plough tripper) →coal bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue
to shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate (All equipments
shutdown immediately except crusher and screen delay for 5s )
Flow 15:#1 coal yard→emergency hopper→C-07belt conveyor→C-4Abelt conveyor(Disc electromagnetic separator) →B roller screen →B ring hammer coal
crusher→C-5Bbelt conveyor(Belt electromagnetic separator) →electric three-way pass B side→C-6Bbelt conveyor (Electric two-side plough tripper) →coal
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Coal Handling System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-013-2009A Page 40 of 40

bunker

01 Program control startup (the downstream equipment starts up first and continue to the
last equipment)

02 Program control shutdown (the upstream equipment will shutdown first and continue to
shutdown to the last step equipment)

03 Trip in any downstream equipment, trip in all upstream equipments

04 Instant shutdown button on DCS actuates (All equipments shutdown immediately except
crusher and screen delay for 5s )

05 Two hard buttons pressed at same time, instant shutdown button actuate(All equipments
shutdown immediately except crusher and screen delay for 5s )

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HL-003

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Review Procedure of Primary Air Fan System
Design
Date DWG No. REV
Scale N/A SCCTI-TS-GL-CS-014-2009A A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 2 of 23

Table of Contents
1. PURPOSE ........................................................................................................................................... 3

2. SCOPE ................................................................................................................................................ 3

3. PREPARATION BASIS .................................................................................................................... 3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .......................................................... 3

5. TOOLS AND INSTRUMENT FOR COMMISSIONING.............................................................. 4

6. PREREQUISITE FOR COMMISSIONING................................................................................... 4

7. MEASURES FOR COMMISSIONING ORGANIZATION .......................................................... 5

8. COMMISSIONING PROCEDURE ................................................................................................. 6

9. SAFETY MEASURES..................................................................................................................... 17

9.1 Safety Rules for Commissioning...................................................................... 17


9.2 Personal Risk and Preventative Measures........................................................ 17
9.3 Equipment Risk and Preventative Measures .................................................... 17

10. APPENDIX ............................................................................................................................... 17

Appendix 1 Commissioning Condition Checklist.......................................................... 18


Appendix 2 Trial operation parameters of PAF and its system ...................................... 20
Appendix 3 Commissioning Record of Control Dampers in PAF and Its System......... 22
Appendix 4 PAF Dampers Commissioning Record ....................................................... 23
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 3 of 23

1. Purpose
1.1 Provide a guideline and set specifications for the commissioning work of system and
equipment so as to guarantee that the system and equipment will be able to put into operation
normally and safely.
1.2 Check the reliability of electric and I&C interlock protection and signal device.
1.3 To check equipment running, verify system performance, and detect and remove any potential
defects.

2. Scope
This procedure is applicable for the commissioning of subsystem for vacuum system,
including such items as the confirmation of air damper, interlocking and protection test,
system commissioning and dynamic adjustment.

3. Preparation Basis
3.1 Installation and operation manual of PAF (primary air fan)
3.2 Installation and operation manual of sealing fan
3.2 Boiler flue-gas and air system diagram
3.3 Control logic diagram of fan

4. Brief Description of System and Equipment


4.1 There are two operating PAFs with guide blade adjusting.
4.2 Technical parameters of PAF

Model of fan: SFG20.5F-C5A Adjustable and centrifugal guide blade


Name and parameters Unit TB BMCR TMCR
Flow at inlet of fan m3/s 84.29 60.21 57.39
Inlet temperature ℃ 50 50 50
3
Medium density Kg/ m 1.08 1.08 1.08
Total pressure of fan PA 18713 13361 12078
Shaft power of fan KW 1973.4 944 822
Total pressure efficiency of fan % 85 87 86
Rotary speed r/min 1490 1490 1490

4.3 Technical parameters of motor

Model of motor YKK630-4 Rated voltage 6300V


Rated power 2000 KW Rated speed 1490 r/min

4.4 Technical parameters of sealing fan


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 4 of 23

Name Item Unit Values


Type High- pressure centrifugal type
Model 926N0 0112D-7
Sealing fan Q'ty Set 2
Full pressure PA 6582
3
Air volume m /h 42221
Model of motor Y315m-4
Power kW 132
Motor of sealing fan Voltage V 380
Current A 225
Rotation speed r/min 1460

5. Tools and Instrument for Commissioning


5.1 Walkie talkie
5.2 Handheld vibration meter
5.3 Clip-on ammeter
5.4 Tachometer

6. Prerequisite for Commissioning


Before formally beginning system commissioning, commissioning persons should conduct
comprehensive checks on conditions that should be available for commissioning of this
system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and
make well the records.
6.1 Environmental Conditions
6.1.1 Within the scope of system, the site should be level, the road should be fluent, the trench
cover is complete and the environment is clean and free of sundries.
6.1.2 Within the scope of system, the plat form, ladder, handrail and guard board are complete, the
scaffolds used for construction have been demolished completely.
6.1.3 The sufficient formal illumination is provided on site, if necessary, the temporary illumination
should be installed additionally.
6.1.4 The reliable communication equipments are provided on site.
6.1.5 The site shall have sufficient quantity of fire fighting equipment and materials.
6.2 Conditions that must be available for machinery provisions
6.2.1 The installation and heat insulation work of all the equipments, pipelines and auxiliary
systems have been completed;
6.2.2 The single commissioning for the PAF and sealing fan is qualified;
6.2.3 The installation and debugging for thin oil station are completed;
6.2.4 The installation and debugging for the industrial cooling water system are completed;
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Procedure of Primary Air Fan System REV A
Commissioning
Procedure
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6.2.5 The sundries inside PAF and system are cleared cleanly;
6.2.6 The equipment and each valve have been tagged and named, conforming to the system.
6.2.7 Each manhole door inside the system is closed.
6.3 Conditions that must be available for electrical and I&C
6.3.1 After the measuring points and measuring elements inside the system are qualified subject to
calibration, they are provided with the application conditions.
6.3.2 After the commissioning for thin oil station is competed, the favorable operation condition,
normal parameters and the correct display of CRT state have been confirmed.
6.3.3 When single commissioning for the valve is completed, the on/off actions are normal and the
on-site location of the limit switch and display of the CRT state are correct.
6.3.4 The interlocking protection alarm test for the system is completed.
6.3.5 The electrical test of motor is qualified, after 2 hour no-load running, the condition is
favorable and the turning direction is correct.
6.4 Other necessary conditions
6.4.1 The joint inspection is performed through organizing such related parties as construction,
Dongfang Electric, employer and production as well as commissioning; the problems found
should be coped completely.
6.4.2 The preparation work for production and commissioning is completed; the operators should
be arranged completely and qualified via the training and examination. The operation
regulation and system diagram are reviewed and approved; the operating tools and the
operation log are prepared properly.
6.4.3 The necessary maintenance tools and materials are prepared;
6.4.4 The command and organizing system for commissioning is perfect, with explicit division of
labor.
6.4.5 The commissioning data, tools, instruments, gauge and the record list are prepared
completely;
6.4.6 The personnel on instrument control, electrical and maintenance from the installation
organization arrive at the site.
6.4.7 The disclosure work on measures is completed.

7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows:
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;

◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;

◆ Hold technical disclosure meeting for commissioning;


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Procedure
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◆ Organize the commissioning work to be carried out by various parties;

◆ Give instructions to operators in the operation;

◆ Prepare commissioning report.


7.2 Responsibilities of Installation Contractor
◆ Be responsible for individual commissioning of equipment and provide relevant record
and certificate of commissioning;
◆ Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;

◆ Be responsible for temporary coordination of local I&C components and connection


terminals.
7.3 Responsibilities of Equipment Manufacturers
◆ Representative of manufacturer, if present on the site offering service, shall provide
technical assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator
◆ Prepare tools to be involved in operation;

◆ Prepare operation log and forms;

◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;
◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;
◆ Be responsible for dealing with the accidents occurred in commissioning。
7.5 Responsibilities of Dongfang Electric
◆ Be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning。


7.6 Responsibilities of Owner
◆ Supervise the execution of commissioning procedures;

◆ Witness the commissioning work;

◆ Accept the results of commissioning。

8. Commissioning Procedure
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Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 7 of 23

8.1 Cold check and transmission test of damper baffle


8.1.1 Check and accept motorized and pneumatic on/off damper baffle and record the following
data:
Check if KKS code, designation and local position indication is correct, if the remote
operation direction and feedback is satisfactory, valve open (close) time, test date and
signature by person in charge of test. Refer to Appendix 4 for detail.
8.1.2 Check the motorized or pneumatic regulating valves and enter the following data on the
records:
KKS code, designation, local position indications and feedback indications corresponding to
upward command of 0%, 50%, 75%, and 100% and downward command of 100%, 75%, 50%
and 0% respectively, confirm if local position indication is correct, test date, signature by
person in charge of test. Refer to Appendix 3 for other requirements.
8.2 Check Interlock Protection and Alarm Check(note: the test project on interlock protection is
based on the logical discuss result.)
8.2.1 The power supply of the PAF shall be placed in the test location to inspect the items below:
(1) Start-up the PAF through computer and feedback on computer is correct;
(2) Stop the PAF through computer and feedback on computer is correct;
(3) Reliable emergency buttons
8.2.2 The interlock protection test of the PAF covers:
8.2.2. 1 Inspection for the allowable condition for PAF A(B) starting

No. Test item Fixed value Results Remarks


Starting condition of PAF A
(1) PAF A is free of tripping condition;
(2) PAF A stops
(3) The control damper at inlet of PAF A is closed properly
(4) The damper at outlet of PAF A has been closed
(5) Without MFT signal
(6) Any forced draft fan is operating
(7) Any induced draft air is operating
(8) Without the alarm signal on high temperature for PAF A
(9) The oil pressure is normal in the oil station for PAF A
(10) The oil station of PAF A allows the main unit starting
(11) The oil station of PAF A is free of signal alarm
(12) The primary air damper at outlet of air preheater A has
opened, or primary air damper at outlet of air preheater B
has opened and the interconnection valve at outlet of
PAF has opened
Starting condition of PAF B
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Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 8 of 23

(1) PAF B is free of tripping condition;


(2) PAF B stops
(3) The control damper at inlet of PAF B is closed properly
(4) The damper at outlet of PAF B has been closed
(5) Without MFT signal
(6) Any forced draft fan is operating
(7) Any induced draft air is operating
(8) Without the alarm signal on high temperature for PAF B
(9) The oil pressure is normal in the oil station for PAF B
(10) The oil station of PAF B is free of signal alarm
(11) The primary air damper at outlet of air preheater B has
opened, or primary air damper at outlet of air preheater A
has opened and the interconnection valve at outlet of
PAF has opened

8.2.2.2 Inspection on tripping condition for the protection interlinking of PAF

No. Test item Fixed value Results Remarks


Tripping condition of PAF A
(1) After PAF A operates for 60s, the outlet damper of PAF
A is closed;
(2) Air preheater A stops
(3) Two forced draft fans and two air induced draft fans stop
uniformly
(4) The vibration of bearing in X-direction at the driving end
of PAF A is high
(5) The vibration of bearing in Y-direction at the driving end
of PAF A is high
(6) The vibration of bearing in X-direction at the
non-driving end of PAF A is high
(7) The vibration of bearing in Y-direction at the non-driving
end of PAF A is high
(8) MFT
(9) Emergency button action
(10) Heavy failure in oil station of PFA A
(11) Oil pump in oil station of PFA A stops completely
(12) The bearing temperature at driving end of PFA A is high
high
(13) The bearing temperature at non-driving end of PFA A is
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 9 of 23

high high
(14) The bearing temperature at motor driving end of PFA A
is high high.
(15) The bearing temperature at motor non-driving end of
PFA A is high high.
(16) The motor stator U- phase temperature of PFA A is high
high.
(17) The motor stator V- phase temperature of PFA A is high
high.
(18) The motor stator W- phase temperature of PFA A is high
high.
Tripping condition of PAF B
(1) After PAF B operates for 60s, the outlet damper of PAF
B is closed;
(2) Air preheater B stops
(3) Two forced draft fans and air induced draft fan stop
uniformly
(4) The vibration of bearing in X-direction at the driving end
of PAF B is high
(5) The vibration of bearing in Y-direction at the driving end
of PAF B is high
(6) The vibration of bearing in X-direction at the
non-driving end of PAF B is high
(7) The vibration of bearing in Y-direction at the non-driving
end of PAF B is high
(8) MFT
(9) Emergency button action
(10) Heavy failure in oil station of PFA A
(11) Oil pump in oil station of PFA B stops completely
(12) The bearing temperature at driving end of PFA B is high
high.
(13) The bearing temperature at non-driving end of PFA B is
high high.
(14) The bearing temperature at motor driving end of PFA B
is high high.
(15) The bearing temperature at motor non-driving end of
PFA B is high high.
(16) The motor stator U- phase temperature of PFA B is high
high.
(17) The motor stator V- phase temperature of PFA B is high
high.
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Procedure of Primary Air Fan System REV A
Commissioning
Procedure
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(18) The motor stator W- phase temperature of PFA B is high


high.

8.2.2.3 Procedure on startup of PAF A/B

No. Test item Fixed value Results Remarks


Procedure on startup of PAF A

(1) Step 1: Start the oil station of fan


(2) Step 2:open the primary air damper at outlet of air
preheater A
(3) Step 3: close the primary air damper at outlet of PAF A
Place the guide blade of PAF A on the minimum
location
(4) Step 4: start the motor of PAF A
(5) Step 5: open the primary air damper at outlet of PAF A
in delay.

Procedure on startup of PAF B


(1) Step 1: Start the oil station of fan
(2)
Step 2: Open the primary air damper at outlet of air
preheater B
(3) Step 3: close the primary air damper at outlet of PAF
B;
Place the guide blade of PAF B on the minimum
location
(4) Step 4: start the motor of PAF B
(5) Step 5: open the primary air damper at outlet of PAF
B in delay.

8.2.2.3 Procedure on shutdown of PAF A/B

No. Test item Fixed value Results Remarks


Procedure on shutdown of PAF A
(1) Step 1: place the guide blade of PAF B on the
minimum location
(2) Step 2: stop the motor of PAF
(3) Step 3: close the primary air damper at outlet of PAF B
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Procedure
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(4) Step 4: stop the oil station of PAF in delay

Procedure on shutdown of PAF B


(1) Step 1: place the guide blade of PAF B on the
minimum location
(2) Step 2: stop the motor of PAF
(3) Step 3: close the primary air damper at outlet of PAF B
(4) Step 4: stop the oil station of PAF in delay

8.2..2.5 Interlock test for the outlet damper of PAF

No. Test item Fixed value Results Remarks


(1) After the PAF is started, interlock and open up the
outlet damper in delay; if the PAF on another side
stops, the outlet damper and the inlet guide blade
should be closed by means of interlock.
(2) After the PAF is started, but the PAF on another is
operating, interlock and close the outlet damper of PAF
and the inlet guide blade.
(3) After the PAF stops completely, interlock and open up
the outlet damper.

8.2.2.6 Interlock test for the cold air damper at outlet of PAF

No. Test item Fixed value Results Remarks


Cold air damper at outlet of PAF A
(1) Conditions on closing by means of interlock
PAF A stops, PAF B operates and the outlet damper of
PAF B fails to close.
Cold air damper at outlet of PAF B
(1) Conditions on closing by means of interlock
PAF B stops, PAF A operates and the outlet damper of
PAF A fails to close.

8.2.2.7 Interlock test for the interconnection valve at outlet of PAF

No. Test item Fixed value Results Remarks


Interconnection valve at outlet of PAF
(1) Conditions on opening by means of interlock
Two PAFs stop completely and delay for 80s or two air
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Procedure of Primary Air Fan System REV A
Commissioning
Procedure
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preheaters are operating and any PAF is operating.


(2) Interlock closing conditions:(or)
(3) Air preheater A stops and PFA B is operating
(4) Air preheater B stops and PFA A is operating
(5) The PAF A stops and delays for 65s, PAF B is
operating, the damper actuator at outlet of PAF A is not
closed and the moving blade of PAF A is not closed
properly.
(6) The PAF B stops and delays for 65s, PAF A is
operating, the damper actuator at outlet of PAFB is not
closed and the moving blade of PAF B is not closed
properly.

8.2.2.8 Interlock test in the oil station of PAF

No. Test item Fixed value Results Remarks


Oil station of PAF A
(1) Allowable start condition in the oil station: the oil level
of oil tank in the oil station isn’t low;
(2) Allowable shutdown condition in the oil station: PAF
A stops and delays for 5 minutes.
(3) When interlock is put into operation, PAF A is
operating and 1# oil pump is operating, the oil pressure
in the oil station of PAF A is low, start 2# oil pump by
means of interlock.
(4) When interlock is put into operation, PAF A is
operating and 2# oil pump trips due to operating
failure, 2# oil pump t in the oil station of PAF A is out
of operation, start 2# oil pump by means of interlock.
(5) When interlock is put into operation, PAF A is
operating and 2# oil pump is operating, the oil pressure
in the oil station of PAF A is low, start 1# oil pump by
means of interlock.
(6) When interlock is put into operation, PAF A is
operating and 2# oil pump trips due to operating
failure, 1# oil pump in the oil station of PAF A is out of
operation, start 1# oil pump by means of interlock.

Heater in the oil station of PAF A


(1) Allowable start condition for the heater in the oil
station: any oil pump in the oil station of PAF A is
operating and the oil level of oil tank in the oil station
for PAF A isn’t low;
(2) Interlocking and starting condition for the heater: when
interlock is put into operation, any oil pump in the oil
station of PAF A is operating and the oil level of oil
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Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 13 of 23

tank in the oil station for PAF A is low;


(3) Interlocking and shutdown condition for the heater:
when interlock is put into operation, the oil level of oil
tank in the oil station for PAF A is high or the oil level
of oil tank is low;
Oil station of PAF B
(1) Allowable start condition in the oil station: the oil level
of oil tank in the oil station isn’t low;
(2) Allowable shutdown condition in the oil station: PAF
B stops and delays for 5 minutes.
(3) When interlock is put into operation, PAF B is
operating and 1# oil pump is operating, the oil pressure
in the oil station of PAFB is low, start 2# oil pump by
means of interlock.
(4) When interlock is put into operation, PAF B is
operating and 1# oil pump trips due to operating
failure, 2# oil pump t in the oil station of PAF B is out
of operation, start 2# oil pump by means of interlock.
(5) When interlock is put into operation, PAF B is
operating and 2# oil pump is operating, the oil pressure
in the oil station of PAF B is low, start 1# oil pump by
means of interlock.
(6) When interlock is put into operation, PAF B is
operating and 2# oil pump trips due to operating
failure, 1# oil pump t in the oil station of PAF B is out
of operation, start 1# oil pump by means of interlock.
Heater in the oil station of PAF B
(1) Allowable start condition for the heater in the oil
station: any oil pump in the oil station of PAF B is
operating and the oil level of oil tank in the oil station
for PAF isn’t low;
(2) Interlocking and starting condition for the heater: when
interlock is put into operation, any oil pump in the oil
station of PAF B is operating and the oil level of oil
tank in the oil station for PAF B is low;
(3) Interlocking and shutdown condition for the heater:
when interlock is put into operation, the oil level of oil
tank in the oil station for PAF B is high or the oil level
of oil tank is low;

8.2.2.9 Inspection on alarm condition of PAF

No. Test item Fixed value Results Remarks


(1) When the bearing temperature of PAF is high, give an
alarm.
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Commissioning
Procedure
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(2) When the bearing temperature of PAF motor is high,


give an alarm.
(3) When the coil temperature of PAF motor is high, give
an alarm.
(4) When the bearing vibrates heavily, give an alarm.
(5) When the oil level of the oil tank in the oil station is
low, give an alarm.
(6) When the oil temperature in the oil station of PAF is
low, give an alarm.
(7) When the oil pressure of lubrication oil is low, give an
alarm.

8.2.2.10 Inspection on interlock protection for sealing fan

No. Test item Fixed value Results Remarks


Sealing fan A
(1) Startup permissive condition of sealing fan A(and)
1) The electrical is free of failure
2) Any fan is operating
3) The inlet damper is les than 5%.
(2) Shutdown permissive condition of sealing fan A (or)
1) The coal mills stop completely
2) Another sealing fan is operating and the pressure is
normal;
(3) Tripping condition of sealing fan A(or)
1) Electrical failure
2) Emergency button action
3) The PAFs stop completely and delay for 15s.
Sealing fan B
(4) Startup permissive condition of sealing fan B (and)
1) The electrical is free of failure
2) Any fan is operating
3) The inlet damper is les than 5%.
(5) Shutdown permissive condition of sealing fan B (or)
1) The coal mills stop completely
2) Another sealing fan is operating and the pressure is
normal;
(6) Tripping condition of sealing fan B(or)
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Commissioning
Procedure
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1) Electrical failure
2) Emergency button action
3) The PAFs stop completely and delay for 15s.
(7) Interlocking and starting condition of sealing fan
1) The backup is put into operation; a sealing fan is
operating and the pressure on the main pipeline of the
air sealing system ≤9kpa, delaying for 1s and starting
the backup sealing fan by means of interlock.
2) The backup is put into operation and a operating
sealing fan trips and start the backup sealing fan by
means of interlock.
(8) Interlocking condition for the outlet valve of sealing
fan
1) The fan on this side operates and delays for 2s,
opening up by means of interlock.
2) The fan on this side operates is out of operation, close
by means of interlock.

8.3 Necessary condition for PAF and prior to system starting


(1) Within the plant, the trench cover is complete, the ladder and the handrail are perfect
and the sundries are cleaned clearly.
(2) The completion for installation of the PAF and system are confirmed, with complete
system.
(3) The air passage of PAF system and the silencer at the inlet are cleared cleanly, free of
the foreign matters to destroy the fan.
(4) The closure for the manhole and inspection hole for the air preheater body and at outlet
of air passage is completed;
(5) The adjustment for the damper and baffle has completed and the acceptance is qualified.
(6) The installation, verification and acceptance for the measuring meter are qualified;
(7) Related transmission test on interlocking protection is qualified, and the constant value
setting for related protection and alarm is completed.
(8) The electrical test for motor has been completed;
(9) The test for the oil station of PAF is completed, conforming to the requirement.
(10) The commissioning for air preheater and system is completed; the commissioning result
conforms to the requirement.
(11) The commissioning for induced draft fan and system is completed; the commissioning
result conforms to the requirement.
(12) The action for the emergency button of fan is reliable.
(13) The PAF and rotator can be turned normally by hands;
(14) The commissioning for the fan and motor monomer is completed, the motor and the
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Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 16 of 23

coupler of fan restore properly.


(15) Each bearing for the fan and motor has sufficient lubricating agent;
(16) The industrial illumination and the accident illumination of equipment are perfect, the
sufficient illumination can be ensured;
(17) The communication system is reliable and the contact is fluent.
(18) The such utility system as the compressed air is provided with the commissioning
condition.
8.4 The commissioning and shutdown for the PAF and system
8.4.1 Check to be completed prior to system startup
(1) Each interlocking test for the fan and the system is qualified;
(2) The on/off for the outlet damper and guide balde is confirmed to be flexible, in addition,
the site openness is consistent with display of CRT.
(3) The insulation for such equipments as the fan is qualified, the power supply is provided;
(4) Various meters for PAF system are put into operation.
(5) The commissioning for the oil pump in the oil station of fan is normal.
错误!链接无效。 The cooling water system is normal;
8.4.2 PAF starting
(1) Close the outlet damper at outlet of fan;
(2) Start the oil station and require that the oil pump motor is provided with feedback
signal;
(3) Shut off the guide blade of fan;
(4) Start the PAF and open up the air damper
(5) Adjust the blade up to the angle required;
(6) Confirm that the sealing fan is provided with the starting condition and start the sealing
fan.
8.4.3 Shutdown of PAF
(1) Shut off the guide blade of fan;
(2) Stop the fan;
(3) Shut off the outlet damper of fan;
(4) Stop the oil pump in the oil station in delay;
8.5 Operation of system during integral start-up
According to the no-load stage, load stage and the full load stage as well as 30-day reliable
operating stage, the reliability for the system operating should be tested.
8.5.1 Dynamic regulation of system
(1) Primary airflow adjusting;
(2) Primary air pressure adjusting;
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Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 17 of 23

8.5.2 Complete trial operation record


Refers to Appendix 2 for the main parameters during stating the commissioning.

9. Safety Measures
9.1 Safety Rules for Commissioning
9.1.1 The parties participating in the commissioning shall be ware of and observe relevant safety
regulations on the site, wear proper clothes and personal safety protection articles.
9.1.2 In case that any accident damages the equipment or hurts person happened or possibly happen
during commissioning, stop commissioning immediately and put the equipment to the lowest
energy state. Then investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning shall obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.1.4 All professional shall be on respective duties during the whole commissioning to guarantee
the safe operation of equipments.
9.2 Personal Risk and Preventative Measures
9.2.1 Injuries might be caused by rotating equipment during commissioning or test. Therefore,
special care must be taken during work and do not touch the rotating components with tools
or your hand.
9.3 Equipment Risk and Preventative Measures
9.3.1 When the PAF and the system start up the commissioning for the first time, the relevant
personnel must be designated to strictly monitor the equipment site, and the reliable
communication means shall be employed to contact with the central control room.
9.3.2 When the PAF is commissioning, the start time and current should be strictly monitored; if the
start time is too long or the current swings abnormally, stop the operation timely;
9.3.3 When starting the PAF, the rotating direction should be noticed, if the turning direction is
opposite, stop the operation timely;
9.3.4 Take notice of monitoring the variation of such parameters as oil pressure, axis temperature
vibration and bearing temperature as well as the current, avoiding producing the severe
accidents.

10. Appendix
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Procedure of Primary Air Fan System REV A
Commissioning
Procedure
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Appendix 1 Commissioning Condition Checklist

Verified Remar
No. Items Requirements Result
by ks
1. Environmental Conditions
(1) Site, road and environment Flat, clear and clean □Yes □No
(2) Platform, ladder, handrail, Complete
□Yes □No
guard plate and scaffold Removed
(3) Illuminating Sufficient □Yes □No
(4) Communication equipment Reliable □Yes □No
(5) Sufficient in quantity and
Fire apparatus □Yes □No
easy for use
2. Maintenance conditions
(1) Installation and heat
All fulfilled □Yes □No
insulation work
(2) Commissioning of fan
Qualified □Yes □No
monomer
(3) Thin oil station The debugging is qualified □Yes □No
(4) Commissioning is
Industrial cooling water completed and
□Yes □No
system commissioning can be
performed.
(5) Inner sundries Completing the clearing □Yes □No
(6) Equipment and valve Tagging, correct naming □Yes □No
(7) Manhole door Closed fully □Yes □No
Electrical and I&C
3.
condition
(1) The calibration is qualified
Measuring points and the
and the indication is □Yes □No
measuring gauge
correct
(2) The operation is favorable
Thin oil station and the display of status is □Yes □No
correct.
(3) After completing the
commissioning, the action
Single valve □Yes □No
is normal, the display of
status is correct.
(4) Interlock protection and
Test eligible □Yes □No
alarm
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Procedure
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(5) The test is qualified,


subject to 2-h no-loading
Electrical test of motor operation, the condition is □Yes □No
favorable and the rotary
direction is correct.
4. Other conditions
(1) Completed, the treatment
Inspection work of system □Yes □No
of defects is completed;
(2) The operators are provided
completely, the operation
Production preparing tools are prepared properly □Yes □No
and the operation log is
prepared properly.
(3) Overhaul tools and
Complete □Yes □No
materials
(4) Command and Perfect, the division of
□Yes □No
organization system work is explicit.
(5) Commissioning data, tools,
instruments, meters and Preparation is complete □Yes □No
record form,
6) Maintenance personnel Sufficient; training passed □Yes □No
(7) Disclosure of measures Fulfilled □Yes □No

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 20 of 23

Appendix 2 Trial operation parameters of PAF and its system


Trial operation parameters of PAF and its system

No. Item Unit Data Remarks

1 %
Moving blade opening, PAF A

2 Motor current, PAF A A

3 KPa
Outlet air pressure, PAF A

4 Differential pressure (DP), PAF A KPa

5 mm/s
Bearing vibration, PAF A

6 Outlet primary air temperature, APH A ℃

7 Inlet primary air temperature, APH A ℃

8 Bearing temperature, PAF A ℃

9 Outlet primary air pressure, APH A KPa

10 Outlet/inlet primary air differential pressure, APH A KPa

11 ℃
Inlet air temperature, PAF A

12 Outlet air temperature, PAF A ℃

13 Motor bearing temperature, PAF A ℃

14 Motor winding temperature, PAF A ℃

15 Moving blade opening, PAF B %

B primary fan current


16 A
Motor current, PAF B
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Primary Air Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-014-2009A Page 21 of 23

17 Outlet air pressure, PAF B KPa

18 Differential pressure (DP), PAF B KPa

19 Bearing vibration, PAF B mm/s

20 Outlet primary air temperature, APH B ℃

21 Inlet primary air temperature, APH B ℃

22 Bearing temperature, PAF B ℃

23 Outlet primary air pressure, APH B KPa

24 Outlet/inlet primary air differential pressure, APH B KPa

25 Inlet air temperature, PAF B ℃

26 Outlet air temperature, PAF B ℃

27 Motor bearing temperature, PAF B ℃

28 Motor winding temperature, PAF B ℃

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Primary Air Fan System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-014-2009A Page 22 of 23

Appendix 3 Commissioning Record of Control Dampers in PAF and Its System


Commissioning Record of Control Dampers in PAF and Its System

Feedback of ascending and descending instruction values


Signa Remar
KKS code Name of damper Date Result
ture ks
0% 25% 50% 75% 100% 75% 50% 25% 0%

X0HFE10AA101XB Moving blade, PAF A

X0HFE20AA101XB Moving blade, PAF B

X0HFW11AA101XB Moving blade, SAF A

X0HFW21AA101XB Moving blade, SAF B

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Primary Air Fan System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-014-2009A Page 23 of 23

Appendix 4 PAF Dampers Commissioning Record


PAF Dampers Commissioning Record

Remote Operating time


Local position Signatu Remark
KKS code Name of damper Directi Feed On Off Date Result
indication re s
on back (Open) (Close)
X0HFE10AA001XB OUTLET MOTORIZED DAMPER, PAF A
X0HFE20AA001XB OUTLET MOTORIZED DAMPER, PAF B
PAF OUTLET INTERCONNECTING
X0HFE30AA001XB
MOTORIZED DAMPER
PAF A OUTLET COOLING AIR
X0HFE11AA001XB
MOTORIZED DAMPER
PAF B OUTLET COOLING AIR
X0HFE21AA001XB
MOTORIZED DAMPER
X0HFW13AA101XB SAF EXHAUST ASH VAVLE

Commissioning Contractor: Date: Operation Contractor: Date:


Construction Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) 0702-00-M-01-QHD-001
DWG No.
PT.PLN(PERSERRO)
PT REKADAYA
JAVA MANAJEMEN
ELEKTRIKA
KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan
DESIGN
Commissioning & Test Institute (2×315MW) Project
STAGE
Approval
Check Procedure of Ash Removal and Deslagging
Review System
Design
Scale DWG No. SCCTI-TS-GL-CS REV
N/A A
Date -015-2009A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 2 of 30

Table of Contents

1. PURPOSE ........................................................................................................................................... 3

2. SCOPE ................................................................................................................................................ 3

3. PREPARATION BASIS .................................................................................................................... 3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .......................................................... 3

5. TOOLS AND INSTRUMENT FOR COMMISSIONING.............................................................. 7

6. PREREQUISITE FOR COMMISSIONING................................................................................... 7

7. MEASURES FOR COMMISSIONING ORGANIZATION .......................................................... 7

8. COMMISSIONING PROCEDURE ................................................................................................. 9

9. SAFETY MEASURES..................................................................................................................... 23

9.1 Safety Rules for Commissioning...................................................................... 23


9.2 Personal Risk and Preventative Measures........................................................ 23
9.3 Equipment Risk and Preventative Measures .................................................... 24

10. APPENDIX ............................................................................................................................... 24

10.1 Appendix 1 Commissioning Condition Checklist............................................ 25


10.2 Appendix2 Valves Commissioning Record...................................................... 26
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Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 3 of 30

1. Purpose
1.1 Provide a guideline and set specifications for the commissioning work of system and
equipment so as to guarantee that the system and equipment will be able to put into operation
normally and safely.
1.2 Check the electrical and I&C protection interlock and signal devices of the ash and cinder and
dust handling system and confirm they are functioning correctly and reliably.
1.3 To check equipment running, verify system performance, and detect and remove any potential
defects.

2. Scope
This procedure applies to commissioning of ash removal and deslagging subsystem of boiler,
including startup commissioning of ash removal and deslagging system and electrostatic
precipitator (ESP).

3. Preparation Basis
3.1 Instructions of equipment relating to deslagging system;
3.2 Instructions of equipment relating to ash removal system;
3.3 Flow diagram and control logic diagram of boiler deslagging system;
3.4 Flow diagram and control logic diagram of boiler ash removal system.

4. Brief Description of System and Equipment


4.1 Brief description of deslagging system and equipment
4.1.1 Dry-type mechanical deslagging system
The deslagging system is designed according to the following technological process: Dry-type
slag remover- Slag crusher -Bucker elevator-Slag storage- Slag truck. Slag from the furnace
continuously enters the upper chute where it has been cooled by air and broken, and then
caught by dry-type slag remover and conveyed to the slag storage by the bucker elevator. In
addition, flying ash from the economizer has also been conveyed to the slag storage.
One slag storage with volume of 100m3 shall be equipped for each boiler. The large sized slag
is conveyed to the double shaft mixer by feeder where it is mixed with water to form the
wetted slag with water content of 25% which has then been conveyed to the slag truck. Large
sized slag shall be transported by self-unloading trucks to the ash yard or other users for
integrated reuse. The ash storage shall be equipped with an auxiliary system consisting of a
bag ash collector and three (3) air cannons to reduce the dust and to ease the slag discharge.
4.1.2 Main equipment and their technical parameters

No. Equipment Q’ty/ Specification / Parameters

1 Dry-type slag One set for each boiler, model: GBL12A×25, capacity: 4-5 t/h
remover with slag pit, large sized slag squeezer, etc.

2 Single roller slag One set for each boiler, capacity: 5.50t/h,5.5KW; power of motor:
crusher 6 kW, 380v.

3 Bucker elevator One set for each boiler, model: ZBT600×22,capacity: 5.50t/h,10
KW; power of motor: 12kw,380v .
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 4 of 30

4 Slag storage One set for each boiler, diameter: Ф7.6m,capacity:100m3


5 Bag ash collector One set for each boiler, power: 7.5KW, volume: 50m3.
Pressure vacuum One set for each boiler, model: 580.
6 relief valve

7 Double shaft mixer One set for each boiler with slide gate and feeder, capacity: 100t/h,
22kw
8 Air reservoir One set for each boiler, C-2/0.8, 2 m3, 0.8MPa
9 Air cannon Three (3) sets for each boiler, model: KL-300

4.2 General Description of Ash removal system and Equipment


The following principles shall be adopted by the ash removal and deslagging system: The
flying ash and slag shall be handled separately; dry flying ash shall be handled keeping its dry
condition; coarse ash and fine ash shall be handled separately. Flying ash shall be collected in
the ash silo where it mixed with water by wet mixer to form the wetted ash with water content
of 15% to 25% and then transported to the ash yard by self unloading trucks or loaded by the
bulk loader into the tank cars and transported to other integrated users.
Two units are designed with one ash removal unit for each boiler, but the control system for
ash removal, compressed air system, facilities and equipment at the ash silo area shall be
shared by two boilers.
4.2.1 Positive pressure dense phase conveying system
This ash removal system adopts the positive pressure and dense phase type dry pneumatic
conveying system. The main equipment for each boiler includes four (4) ash conveyers under
the economizer ash hopper ( ash tanks), forty (40) conveyers (conveyer hoppers) under the
ash hoppers of 1#, 2#, 3# and 4# fields of ESP (8 for each field). The ash hoppers are
equipped with two (2) gasification fans each of which is equipped with an electric heater. The
system also includes ash conveying pipelines, domed valve, slide gate valve, pneumatic valve,
pneumatic change-over valve, conveying air compressor, refrigerated air dryer, air storage
system, electrical equipment, PLC control system, etc.
The air needed for dry ash conveying is supplied by four (4) air compressors specially used
for ash conveying and the air source for the control system is furnished by the instrument
service air compressors. Dry ash collected by the economizer and ESP shall conveyed through
conveying pipeline by the air compressor to the slag storage and two (2) ash silos separately.
Each silo is equipped with a pulse bag ash collector, two (2) level gauges. The fluidizing air
for the ash silo is supplied by two (2) gasification fans and each silo is equipped with a bulk
loader and a double shaft mixer.
The conveyer hoppers for all fields of each ESP have the group operation respectively and the
conveying system of each ESP shall be divided into four groups (A,B,C and D). One pipeline
is specially used for ash conveying of the field 1, one pipeline is for economizer and one
pipeline is commonly used by the fields 2,3 and 4 for ash conveying. Each boiler has a main
pipeline for ash conveying.
All equipment of the flying ash conveying system shall be able to handle the maximum
quantity of flying ash produced under the boiler operating condition of MCR with a sufficient
surplus capacity. The system could be operated either continuously or intermittently and its
down period has been considered.
4.2.2 The air compressor house and fluidized air system for ESP
Two boilers shares one air compressor house in which three (3) screw air compressors (two
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 5 of 30

for operation and one for standby, with function of automatic pressure control) three (3)
refrigerated air dryers and three (3) air reservoirs are installed. Two (2) ash hopper
gasification fans and two (2) ash hopper heaters have been equipped for each ESP. The
refrigerated air dryers and air compressors are connected using the piping-main scheme. The
air entering the refrigerated air dryers (two in operation and one in standby) shall be
controlled by its inlet valve to get quality of the air.
4.2.3 Ash silo, its fluidization, dust collection and ash unloading system
Two silos shall be shared by two boilers. The bottom of the silo is of flat type with a fluidizing
chute set on it for smooth ash disposal. The fluidizing air shall be supplied by the two (2) silo
gasification fans (one is in operation and other is for standby) with one electric air heater
installed at the outlet of each of it that can heat the fluidizing air to about 150℃. On the top of
the ash silo there are two (2) bag dust collectors used to purify the exhaust. There are two (2)
double shaft mixers installed on the bottom of the ash silo in which the ash is mixed with
water to form the wetted ash with water content of 25% which has then been transported to
the ash yard for storage or used by the integrated users. There is also one bulk loader used for
taking the dry ash for use when necessary. Considering that the dry ash loading job is
intermittent one, the equipment at ash silo area will be locally controlled and their operating
conditions will be remotely monitored. One bag dust collector shall be equipped on the top of
each of the two ash silos. The silo is equipped with high/low and continuous level signal
devices and the instrument air of ash silo will come from the instrument service air.
4.2.4 Main equipment and its technical parameters

Design Parameters
No Name Qty. /Model
. Flow Pressure

1 Screw air compressor 3 sets for 2 boilers. 21m3/min 0.75MPa


LS25S-300LWC-SULL

2 Refrigerated air dryer 3 sets for 2 boilers. 30m3/min 0.8MPa


JRL-50NW,5KW
Prefilter 3 sets for 2 boilers. JHF9-30 30m3/min 0.8MPa
3
3 Afterfilter 3 sets for 2 boilers. JHF9-30 30m /min 0.8MPa
3
Air reservoir One set for two boilers. Model: 20m 0.8MPa
C-20/0.8
3 sets for 2 boilers. 6m3 0.8MPa
4 Air reservoir
Model: C-6/0.8

5 Gasification fan Four for two boilers. 11.9m3/min 0.0784MPa


BKD-3000,30KW

6 Air electric heater Six sets for two boilers. 45KW, 11.9m3/min 0.0784MPa
380V
7 Ash transmitter of field 1 Eight sets for two boilers. Capacity: 9.5T/H
8 Ash transmitter of field 2 Eight sets for two boilers. Capacity: 6.3T/H
9 Ash transmitter of field 3 Eight sets for two boilers. Capacity: 1.27T/H
10 Ash transmitter of field 4 Eight sets for two boilers. Capacity: 0.24T/H
Two sets for two boilers. Capacity: 100T/H,
11 Double shaft mixer P=22KW
Model: SZ200
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 6 of 30

Two sets for two boilers. Capacity: 8.42Nm3/h,


12 Gasification fan 88.2KPa
Model: GCH-A-60

13 Gasification Box of ash Sixty four sets for two boilers. 300X300
hopper
14 Ash silo Two sets for two boilers. 500 m3
15 Bag dust collector Two sets for two boilers. 80 m3

16 Pressure vacuum relief Two sets for two boilers. Model: 508
valve
17 Bulk loader Two sets for two boilers. Capacity: 100T/H

4.2.5 Slag Composition of Design Coal

No. Name Symbol Unit Designed coal Variation range of


type coal type
1 Silica SiO2 % 11.7 10--32
2 Ferric oxide Fe2O3 % 34 8.3--38.5
3 Alundum Al2O3 % 12 2.63-29.2
4 Calcium oxide CaO % 14 4.18--20
5 Magnesium oxide MgO % 12 8.30--16
6 Titanic oxide TiO2 % 0.3 0.10--0.7
7 Sulfur trioxide SO3 % 13.67 0.12--15
8 Phosphorus pentasulfide P2O5 % 1.15 0.5--22.7
9 Sodium oxide Na2O % 0.19 0.15--2
10 Potassium oxide K2O % 0.98 0.05--2.4
11 Melting point of ash
(1) Distortion temperature DT ℃ 1150 1150
(2) Softening temperature ST ℃ 1200 1200
(3) Melting temperature FT ℃ 1300 1300

4.3 General description of rejects handling system


Each boiler shall be equipped with five (5) medium speed mills for coal pulverizing system of
this phase of project each of which shall have a rejects discharge gate valve and a rejects
discharge hopper with volume of 0.5 m3. During the normal operation the mill rejects will be
discharged with help of a self-unloading trolley by manual operation.
4.4 Brief introduction to the ESP system
Each unit shall be equipped with one ESP of horizontal type with two compartments and four
fields and each ESP shall have sixteen (16) large sized ash hoppers. The positive pressure and
dense phase pneumatic conveying mode shall be adopted by ESP.
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 7 of 30

Working principle: During the period of the dusty flue gas passing through the high-voltage
fields, the dust particles colliding with basic and negative ions and electrons between
electrodes or in the ion diffusion movement become a kind of particles carrying electrons and
ions that moves toward the opposite electrode and have been adsorbed on them under forces
of the electrical fields. Such dust particles could be dropped into the ash hoppers by rapping
the electrode plates.

5. Tools and Instrument for Commissioning


5.1 Walkie talkie;
5.2 Portable vibration meter;
5.3 Digital multimeter.

6. Prerequisite for Commissioning


Before formally beginning system commissioning, commissioning persons should conduct
comprehensive checks on conditions that should be available for commissioning of this
system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and
make well the records.
6.1.1 The installation work for the system and all equipment has been completed.
6.1.2 All foreign matters inside the system and equipment have been cleaned up.
6.1.3 Eight (8) hours test operation for each single equipment has been completed and all defects
have been eliminated.
6.1.4 Air ventilation test has been completed and all defects have been eliminated.
6.1.5 Forty eight (48) hours aeration-drying for ash silo has been finished.
6.1.6 The pneumatic and hand-operated valves position indication conforms to their real position
proved by operating of them.
6.1.7 All ash conveying pipelines have been purged by the air pressure test.。
6.1.8 Commissioning of I&C, level gauges, pressure switches, etc. has been finished and is ready
for operation
6.1.9 All safety valves of the system completely equipped and have been calibrated for satisfaction.
6.1.10 Commissioning of PLC system is finished and it has a correct logic relationship.
6.1.11 Commissioning of interlock and audio & visual alarm device has been finished and tested for
satisfaction.
6.1.12 The site should have smooth service passage and sufficient lighting
6.1.13 Communication equipment is sufficient for use and its performance is reliable.
6.1.14 Fire-fighting equipment is sufficient and convenient for use.
6.1.15 Overhaul tools and materials with great varieties are sufficient for use.
6.1.16 Tools and instrument for commissioning have well been prepared.

7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 8 of 30

work responsibilities so as to guarantee safe and effective implementation of commissioning.


The division of works is as follows:
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;

◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;

◆ Hold technical disclosure meeting for commissioning;

◆ Organize the commissioning work to be carried out by various parties;

◆ Give instructions to operators in the operation;

◆ Prepare commissioning report.


7.2 Responsibilities of Installation Contractor
◆ Be responsible for individual commissioning of equipment and provide relevant record
and certificate of commissioning;
◆ Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;
◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;

◆ Be responsible for temporary coordination of local I&C components and connection


terminals.
7.3 Responsibilities of Equipment Manufacturers
◆ Representative of manufacturer, if present on the site offering service, shall provide
technical assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator
◆ Prepare tools to be involved in operation;

◆ Prepare operation log and forms;

◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;
◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;
◆ ¡¡Be responsible for dealing with the accidents occurred in commissioning。
7.5 Responsibilities of Dongfang Electric
◆ Be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Procedure
SCCTI-TS-GL-CS-015-2009A Page 9 of 30

◆ Organize analysis and settlement of major technical issues in commissioning.


7.6 Responsibilities of Owner
◆ Supervise the execution of commissioning procedures;

◆ Witness the commissioning work;

◆ Accept the results of commissioning.

8. Commissioning Procedure
8.1 Cold check and transmission test of valve
8.1.1 Check the motorized on-off valves and enter the following data on the records:
KKS code, designation, confirming if the local position indication is correct, open/close time
of valves, test date, signature by person in charge of test. Refer to Appendix 2 for other items.
8.1.2 Check and accept pneumatic switching gate (valves) and record the following data:
KKS code, designation, confirming if local position indication is correct, if the operating
direction on the computer and the remote feedback are correct, test date, signature by person
in charge of test. Refer to Appendix 2 for other items
8.2 Checking of interlocking and alarm system ( Note: The interlocking test items are subject to
the result of the discussion on logic.)
Set the power at “TEST” position to check the following items:
(1) Start the equipment from the computer and have a correct feedback on it.
(2) Stop the equipment from the computer and have a correction feedback on it.
(3) Emergency pushbutton worked reliably.
8.3 Checking of the interlocking and protection system of the ash removal system.
8.3.1 Ash hopper gasification fan system
Operation mode: 1 in operation, 1 in standby

No. Test item Fixed value Results Remarks

(1) 1# Electric heater startup condition: gasification


fan in operation

(2) 1# Gasification fan startup condition: free of fault


and remote control is possible

(3) 1# Gasification fan shutdown condition: electric


heater shutdown

(4) 1#Gasification fan tripping, interlocked shutdown


of electric heater

(5) 2# Electric heater startup condition:2#


Gasification fan is in operation

(6) 2# Gasification fan startup condition: fault free


and remote

(7) 2# Gasification fan shutdown condition: electric


heater shutdown
(8) 2# Gasification fan tripping, interlocked
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 10 of 30

shutdown of electric heater


Enable interlocking to open outlet valve of 2#
(9) gasification fan and gives an alarm and start 2#
standby gasification fan when 1# gasification fan
tripping or stopped.
Enable interlocking to open outlet valve of 1#
(10) gasification fan and gives an alarm and start 1#
standby gasification fan when 2# gasification fan
tripping or stopped.

8.3.2 Ash silo gasification fan system


Operation mode: 1 in operation, 1 in standby

No. Test item Fixed value Results Remarks

(1) 1# Electric heater startup condition: gasification


fan in operation

(2) 1# Gasification fan startup condition: fault free


and remote

(3) 1# Gasification fan shutdown condition: electric


heater shutdown

(4) 1# Gasification fan tripping, interlocked


shutdown of electric heater

(5) 2# Electric heater startup condition:2#


Gasification fan is in operation

(6) 2#Gasification fan startup condition: fault free


and remote

(7) 2# Gasification fan shutdown condition: electric


heater shutdown

(8) 2# Gasification fan tripping, interlocked


shutdown of electric heater
Enable interlocking to open outlet valve of 2#
(9) gasification fan and gives an alarm and start 2#
standby gasification fan when 1# gasification fan
tripped or stopped.
Enable interlocking to open outlet valve of 1#
(10) gasification fan and gives an alarm and start 1#
standby gasification fan when 2# gasification fan
tripped or stopped.

8.3.3 Air compressor system for ash handling


Operation mode: 2 in operation, 1 in standby

No. Test item Fixed value Results Remarks


3# Air compressor started by interlocking when 又
(1) 1# and 2# compressor in operation but the
pressure becomes low and interlocking enable.
(2) 2# Air compressor started by interlocking when1#
and 3# compressor in operation but the pressure
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 11 of 30

becomes low and interlocking enabled.


1# Air compressor start by interlocking when 2#
(3) and 3# compressor in operation but the pressure
becomes low and interlocking enabled.

8.3.4 Refrigerated type dryer system


Operation mode: 2 in operation, 1 in standby

No. Test item Fixed value Results Remarks


3# Refrigerated air dryer start and its outlet valve
(1) opened by interlocking when 1# & 2# refrigerated
air dryer in operation but any one of them stopped
by fault.
1# Refrigerated air dryer start and its outlet valve
(2) opened by interlocking when 2# & 3# refrigerated
air dryer in operation but any one of them stopped
by fault.
2# Refrigerated air dryer start and its outlet valve
(3) opened by interlocking when 1# & 3# refrigerated
air dryer in operation but any one of them stopped
by fault

8.3.5 Ash silo discharging system

No. Test item Fixed value Results Remarks

(1) Startup condition of 1# feeder:1# Double shaft


mixer is in operation

(2) Opening condition of 1# pneumatic gate valve:1#


feeder is in operation

(3) 1# Double shaft mixer tripping condition:


water-break or overload protection action
1# Double shaft mixer tripping to shutdown
(4) feeder and pneumatic gate valve through
interlocking

(5) Startup condition of 2# feeder:2# Double shaft


mixer is in operation

(6) Opening condition of 2# pneumatic gate valve:2#


feeder is in operation

(7) 2# Double shaft mixer tripping condition:


water-break or overload protection action
1# Feeder and 1# Pneumatic flashboard stopped
(8) by interlocking when 2# Double shaft mixer
tripped.

8.3.6 Programmed control test of ash removal system


8.3.6.1 Checklist of electric field #1 logic
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Procedure
SCCTI-TS-GL-CS-015-2009A Page 12 of 30

No Inspection contents Result

Initial status (condition) of electric field #1 under programmed control operation


01 Program control position of supervisory computer
02 Set local control box to program control position
03 Instrument air pressure is normal
04 Storage top ash pipe changeover valve is in operation
05 Bag type dust collector (heater) is in operation
06 Ash silo has no high level alarm
07 Feed sealing valve pressure is low
Feed sealing valve pressure low Confirm status of valves when electric field #1 system operation
is stopped or at initial status
01 MD pump feed valve in close position
02 MD pump vent valve in close position

03 Transfer pipe discharge, gulp valve and secondary air valve are in
close position
04 Feed sealing valve is closed
Flow of electric field #1 programmed control
01 Send programmed control start command

02 Confirm that programmed operation initial status (condition) is


met

03 Confirm that the initial status of all valves is correct for the
programmed control

04 Open feeding of all the MD pump inlet dome valves and air
bleeding valves at the same time for the electric field

05 Feed for 3s. Any storage pump high level signal arrives or feed
time is delayed by another 10s.

06 Close the feed of all the MD inlet dome valves and the air bleeding
valves of the electric field (delayed by 5s)

07 Pressurize feed sealing valve (delayed by 3s) until inflation


pressure is met
08 Open #1 electric field discharge valve (delayed by 4s)

09 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)
10 Transfer pipe pressure low signal arrives

11 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
12 Close discharge valve
13 Re-enter the next cycle
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 13 of 30

Electric field #1 transfer pipe clogged, program automatically goes to clogging removal cycle
period

01 In case the pressure of transfer pipe in Item 10 within a cycle


period is high, go to clogging removal cycle

02 Close transfer air valve, gulp valve and secondary air valve
simultaneously
03 Transfer pressure is lower than 0.06MPa.
04 Close ash pipe pressure relief valve (delay by 3s)

05 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)

06 Transfer pipe pressure low signal arrives; Otherwise, go back to


Step 02 and then to clogging removal procedure again

07 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
08 Close discharge valve
09 Re-enter the next cycle
In case transfer time exceeds 600s, give alarm, and the system will
10 automatically reset. Manual clogging removal shall be carried out
before carrying out programmed ash removal

8.3.6.2 Checklist of electric field #2 ash handling logic

No Inspection contents Result

Initial status (condition) of #2 electric field programmed operation)


01 Program control position of supervisory computer
02 Set local control box to programmed control position
03 Instrument air pressure is normal
04 Storage top ash pipe changeover valve is in operation
05 Bag type dust collector (heater) is in operation
06 Ash silo has no high level alarm
07 Feed sealing valve pressure is low
Confirm status of valves when electric field #2 system is shutdown or at initial status
01 MD pump feed valve is in close position
02 MD pump air bleeding valve is in close position

03 Transfer pipe discharge, gulp valve and secondary air valve are in
close position
04 Feed sealing valve is closed
Flow of electric field #2 programmed control
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 14 of 30

01 Send programmed control start command

02 Confirm that programmed operation initial status (condition) is


met

03 Confirm that the initial status of valves is correct for the


programmed control

04 Open feeding of all the MD pump inlet dome valves and air
bleeding valves at the same time for the electric field

05 Feed for 3s. any storage pump high level signal arrives or feed
time is delayed by another 10s.

06 Close the feed of all the MD inlet dome valves and the air bleeding
valves of the electric field (delayed by 5s)

07 Pressurize feed sealing valve (delayed by 3s) until inflation


pressure is met
08 Open discharge valve (delay by 4s)

09 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)
10 Transfer pipe pressure low signal arrives

11 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
12 Close discharge valve
13 Re-enter the next cycle
Electric field #2 transfer pipe is clogged. The program goes automatically to clogging removal
cycle period

01 In case the pressure of transfer pipe in Item 10 within a cycle


period is high, go to clogging removal cycle period

02 Close transfer air valve, gulp valve and secondary air valve
simultaneously
03 Transfer pressure is lower than 0.06MPa.
04 Close ash pipe pressure relief valve (delay by 3s)

05 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)

06 Transfer pipe pressure low signal arrives; Otherwise, go back to


Step 02 and then to clogging removal procedure again

07 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
08 Close discharge valve
09 Re-enter the next cycle
In case transfer time exceeds 600s, give alarm, and the system will
10 automatically reset. Manual clogging removal shall be carried out
before carrying out programmed ash removal

8.3.6.3 Checklist of electric field #3 ash handling logic


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 15 of 30

No. Inspection contents Result


Initial status (condition) of #3 electric field programmed operation)
01 Program control position of supervisory computer 又
02 Set local control box to program control position
03 Instrument air pressure is normal
04 Storage top ash pipe changeover valve is in operation
05 Bag type dust collector (heater) is in operation
06 Ash silo has no high level alarm
07 Feed sealing valve pressure is low
Confirm status of valves when electric field #3 is shutdown or at initial status
01 MD pump feed valve in close position
02 MD pump air bleeding valve is in close position

03 Transfer pipe discharge, gulp valve and secondary air valve are in
close position
04 Feed sealing valve is closed
Flow of electric field #3 programmed control
01 Send programmed control start command

02 Confirm that programmed operation initial status (condition) is


met

03 Confirm that the initial status of valves is correct for the


programmed control

04 Open feeding of all the MD pump inlet dome valves and air
bleeding valves at the same time for the electric field

05 Feed for 3s. Any storage pump high level signal arrives or feed
time is delayed by another 10s.

06 Close the feed of all the MD inlet dome valves and the air bleeding
valves of the electric field (delayed by 5s)

07 Pressurize feed sealing valve (delayed by 3s), inflation pressure is


met

08 Depressurize discharge sealing valve (delayed by 5s), air pressure


low is met
09 Open discharge valve (delayed by 6s)

10 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delay by 20s)
11 The condition that transfer pipe pressure low signal arrives is met

12 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delay by 8s)
13 Close discharge valve (delay by 5s)
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 16 of 30

14 Pressurize discharge sealing valve. Air pressure high is met


15 Re-enter the next cycle
Transfer pipeline of electric field #3 is clogged,. Program goes automatically to clogging removal
cycle period

01 Go to clogging removal cycle period if transfer pipe pressure is


high in Item 11 within a cycle period

02 Close transfer air valve, gulp valve and secondary air valve
simultaneously and open ash pipe pressure relief valve
03 Transfer pressure is lower than 0.06MPa.
04 Close ash pipe pressure relief valve (delay by 3s)

05 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)

06 Transfer pipe pressure low signal arrives. Otherwise, go back to


Step 02 and then to clogging removal procedure again

07 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
08 Close discharge valve
09 Re-enter the next cycle
In case transfer time exceeds 600s, give alarm, and the system will
10 automatically reset. Manual clogging removal shall be carried out
before carrying out programmed ash removal

8.3.6.4 Checklist of electric field #4 ash handling logic

No. Inspection contents Result


Electric field #4 programmed control initial status (condition)
01 Program control position of supervisory computer
02 Set local control box to program control position
03 Instrument air pressure is normal
04 Storage top ash pipe changeover valve is in operation
05 Bag type dust collector (heater) is in operation
06 Ash silo has no high level alarm
07 Feed sealing valve pressure is low
Confirm status of valves when electric field #4 system is shutdown or at initial status
01 MD pump feed valve is in close position
02 MD pump air bleeding valve is in close position

03 Transfer pipe discharge, gulp valve and secondary air valve are in
close position
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 17 of 30

04 Feed sealing valve is closed


Flow of electric field #4 programmed control
01 Send programmed control start command

02 Confirm that programmed operation initial status (condition) is


met

03 Confirm that the initial status of valves is correct for the


programmed control

04 Open feeding of all the MD pump inlet dome valves and air
bleeding valves at the same time for the electric field

05 Feed for 3s. any storage pump high level signal arrives or feed
time is delayed by another 10s.

06 Close the feed of all the MD inlet dome valves and the air bleeding
valves of the electric field (delayed by 5s)

07 Pressurize feed sealing valve (delayed by 3s), inflation pressure is


met

08 Depressurize discharge sealing valve (delayed by 5s), air pressure


low is met
09 Open discharge valve (delayed by 6s)

10 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)
11 The condition that transfer pipe pressure low signal arrives is met

12 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delay by 8s)
13 Close discharge valve (delay by 5s)
14 Pressurize discharge sealing valve. Air pressure high is met
15 Re-enter the next cycle
Electric field #4 transfer pipe is clogged. The program goes automatically to clogging removal
cycle period

01 Go to clogging removal cycle period if transfer pipe pressure is


high in Item 11 within a cycle period

02 Close transfer air valve, gulp valve and secondary air valve
simultaneously and open ash pipe pressure relief valve
03 Transfer pressure is lower than 0.06MPa.
04 Close ash pipe pressure relief valve (delay by 3s)

05 Open transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 20s)

06 Transfer pipe pressure low signal arrives. Otherwise, go back to


Step 02 and then to clogging removal procedure again

07 Close transfer air valve, gulp valve and secondary air valve
simultaneously (delayed by 8s)
08 Close discharge valve
09 Re-enter the next cycle
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 18 of 30

In case transfer time exceeds 600s, give alarm, and the system will
10 automatically reset. Manual clogging removal shall be carried out
before carrying out programmed ash removal

8.3.6.5 Checklist of economizer ash handling logic

No. Inspection contents Result


Economizer fly ash settler programmed operation initial status (condition)
01 Program control position of supervisory computer
02 Set local control box to program control position
03 Instrument air pressure is normal
04 Storage top ash pipe valve is in operation
05 Bag type dust collector (heater) is in operation
06 Ash silo has no high level alarm
07 Feed sealing valve pressure is low
Confirm status of valves when economizer fly ash settler is shutdown or at initial status.
01 MD pump feed valve is in close position
02 MD pump air bleeding valve is in close position

03 Transfer pipe discharge, gulp valve and secondary air valve are in
close position
04 Feed sealing valve is closed
Flow of economizer fly ash settler programmed control
01 Send programmed control start command

02 Confirm that programmed operation initial status (condition) is


met

03 Confirm that the initial status of valves is correct for the


programmed control
04 Open the feeding of all the MD inlet dome valves of fly ash settler

05 Feed for 3s. any storage pump high level signal arrives or feed
time is delayed by another 10s.

06 Close the feeding of all the MD pump inlet dome valves of fly ash
settler (delayed by 5s)

07 Pressurize feed sealing valve (delayed by 3s), inflation pressure is


met
08 Open discharge valve of fly ash settler (delayed by 4s)

09 Open transfer air valve, gulp valve simultaneously (delayed by


20s)
10 Fly ash settler transfer pipe pressure low signal arrives
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 19 of 30

11 Close transfer air valve and gulp valve simultaneously (delayed by


8s)
12 Close discharge valve (delayed by 2s)
13 Re-enter the next cycle
Economizer fly ash settler transfer pipe is clogged. The program automatically goes to clogging
removal cycle period

01 In case the pressure of transfer pipe in Item 10 within a cycle


period is high, go to clogging removal cycle period

02 Close transfer air valve, gulp valve and open ash pipe pressure
relief valve simultaneously
03 Transfer pressure is lower than 0.06MPa.
04 Close ash pipe pressure relief valve (delay by 3s)

05 Open transfer air valve, gulp valve simultaneously (delayed by


20s)

06 Transfer pipe pressure low signal arrives. Otherwise, go back to


Step 02 and then to clogging removal procedure again

07 Close transfer air valve and gulp valve simultaneously (delayed by


8s)
08 Close discharge valve
09 Re-enter the next cycle
In case transfer total time exceeds 600s, gives alarm. System will
10 reset automatically. Manual clogging removal shall be carried out
before carrying out programmed ash removal

8.4 Checking of the interlocking and protection of deslagging system


8.4.1 Dry-type slag remover

No. Test item Fixed value Results Remarks


Conditions for the dry-type slag remover start-up
(1) Set at “REMOTE”
(2) No protective trip conditions
(3) Slag crusher is already in operation
Interlock Protection and Alarm of Dry Type Slag Remover
(1) Chain break of slag remover, slag remover
tripping, and alarm
(2) Over-temperature of slag remover, slag remover
tripping, and alarm
(3) Slag crusher trip or shutdown by fault, slag
remover shutdown, and alarm
(4) Emergency button shutdown (local), tripping,
alarm
(5) Electrical protection actuation, tripping, alarm
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 20 of 30

8.4.2 Slag crusher

No. Test item Fixed value Results Remarks


Slag crusher startup condition
(1) Slag crusher set to remote
(2) No protective trip conditions
(3) Bucket elevator is in operation
Slag crusher interlock protection and alarm
(1) Slag crusher locked, tripping, alarm
(2) Slag crusher overload or electrical protection
action, tripping, alarm
(3) Emergency button shutdown (local)

8.4.3 Bucket elevator

No. Test item Fixed value Results Remarks


Bucket elevator startup condition
(1) Bucket elevator is set to remote
(2) No protective trip conditions
Bucket elevator interlock protection and alarm
(1) Bucket elevator locked, tripping, alarm
(2) Slag crusher overload or electrical protection
action, tripping, alarm
(3) Emergency button stop

8.4.4 Slag storage

No. Test item Fixed value Results Remarks


(1) Slag storage high level, alarm
(2) Slag storage rapping (1, 2, 3) startup (local,
remote)
(3) Slag storage rapping (1, 2, 3) shutdown (local,
remote)

8.4.5 Double shaft mixer

No. Test item Fixed value Results Remarks


(1) Startup condition of feeder: Double shaft mixer is
in operation
(2) Opening condition of pneumatic gate valve: The
feeder is in operation
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 21 of 30

(3) Double shaft mixer tripping condition: water-break


or overload protection action
(4) Double shaft mixer tripping to shutdown feeder
and pneumatic gate valve through interlocking

8.5 Deslagging system in operation and shutdown


8.5.1 Check to be completed prior to system startup
(1) Confirm that the interlock test result for ash removal system is acceptable.
(2) Make sure that all defects have been eliminated.
(3) Make sure that all equipment have been energized.
(4) Make sure that all kinds of instrument has been put into operation.
8.5.2 Putting the deslagging system into operation
(1) Slag storage is available with slag intake condition. Interlocking is put into operation.
(2) Make sure that the bucker elevator meets its start-up condition and has been started with
the speed well adjusted.
(3) Make sure that the slag crusher meets its start-up condition and has been started.
(4) Make sure that the dry-type slag remover meets its start-up condition and has been
started with the speed well adjusted.
8.5.3 Stop operation of the deslagging system
(1) Stop the dry-type slag remover after revolution drop.
(2) Stop the slag crusher.
(3) Stop the bucker elevator after revolution drop.
8.5.3 Carry out combined commissioning of system equipment
When the defects found in the startup and commissioning have been eliminated, restart the
deslagging system equipment for combined operation.
8.6 Startup and shutdown of the ash removal system
8.6.1 Check to be completed prior to system startup
(1) Confirm that the interlock test result for ash removal system is acceptable.
(2) Make sure that the programmable control for all fields of ash removal system has been
tested for satisfaction.
(3) Make sure that all defects have been eliminated.
(4) Make sure that all equipment have been energized.
(4) Make sure that all kinds of instrument has been put into operation.
8.6.2 Put the ash removal system into operation
(1) Preparing to put the ash removal system into operation after the boiler ignition.
(2) Make sure that the ash silo meets the conditions to receive the ash.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 22 of 30

(3) Make sure that the conditions for startup of bag ash collector and silo gasification fan
have been met. Start them and make the interlocking enabled when they are running
well.
(4) Make sure that the conditions for startup of air compressor and refrigerated air dryer
have been met. Start them and make the interlocking enabled when they are running
well.
(5) Make sure that the air pressure for instrument and ash removal meets the requirement.
(6) Make sure that the conditions for startup of ash hopper gasification fan and electric
heater have been met. Start them and make the interlocking enabled when they are
running well.
(7) Have the ash removed from the ash lines of all fields and economizer under the control
of PLC program.
8.6.3 Stop the ash removal system
(1) After the boiler shutdown have the ash removal system operated for thirty (30) minutes
and make sure that all hoppers have been emptied.
(2) Stop the ash removal operation of lines of all fields and economizer controlled by PLC
program separately.
8.7 Commissioning of electrostatic precipitator (ESP) system
8.7.1 Rapping test for cathode and anode plates
(1) Have the motor of cathode and anodes ran for two (2) hours without load, check and
eliminate the defects, such as abnormal temp. rise, vibration and/or noise if discovered.
(2) Make the whole rapping system test, check and correct any bind-seize if discovered.
(3) Check the rotation direction during the test and contrarotation is not allowed.
(4) Start the line shafting of cathode and anode and press the emergency pushbutton when
the motor has reached its full speed. If the line shafting does not run for one revolution,
take the test run once again following the above procedures. If no any abnormality
found, contact the electrical operator to switch it in for a continuous operation.
(5) Have the equipment tested for one hour and then shut down for complete inspection and
prepare to take the adjust of the rapping timing.
(6) Follow the specified value by the manufacturer to adjust the rapping timing for cathode
and anode for satisfaction to complete the test.
(7) Round-off work: Have all motors de-energized and lock the local switch. Seal the hole
for rapping shaft and clear up remaining foreign matters during the test operation.
8.7.2 Commissioning of the energized electric heater for ESP
(1) The AC withstand test and insulance measurement for the electric heaters hall be taken
before commissioning with test voltage of 2,000 V and insulance not less than 50mΩ.
(2) Make the electric heater energized and check if there is any short circuit existed and
whether the range of temperature control was correct, and the temperature climbing
speed.
8.7.3 ESP no-load boosting test
Cooperate with the electrical specialty.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 23 of 30

8.7.4 Handling of coherent ash before putting the ESP into operation
8.7.5 Conditions for operation of ESP
(1) Putting the heating devices for insulators and rapping porcelain shaft housings for the
discharge electrodes and ash hoppers into operation twelve (12) hours ahead of the
boiler ignition.
(2) No operation of any field of ESP permitted when the oil is taken as the only fuel for the
boiler, and the rapping equipment needs to be ran continuously.
(3) When the first set of coal pulverizing system entering a normal operation, put the ESP’s
fields into operation one by one according to the PLC’s program and have the rapping
equipment changed to periodical operation provided the following on-site conditions are
met:
The burners have been atomized well and have satisfied ignition;
The waste-gas temperature is higher than 110℃;
No dark smoke discharged from the chimney.
8.7.6 Shutting down of the ESP
(1) Stop operation of ESP’s fields one by one and have the rapping equipment of them
changed to continuous operation under the following conditions:
Coal and oil co-fired during the period of the boiler shutting down;
The waste-gas temperature is lowered to 110℃.
(2) All fields have to be stopped when the oil is used as the only fuel of the boiler.
(3) After the induced draft fan (IDF) stopped keep a continuous operation of the rapping
equipment to empty the ash hoppers. Stop operation of all heaters.
8.8 System operation at the stages of the whole set start-up
Have the system’s reliability tested in different operation stages of no load, partial load, full
load and thirty (30) days continuous operation.

9. Safety Measures
9.1 Safety Rules for Commissioning
9.1.1 The parties participating in the commissioning will be ware of and observe relevant safety
regulations on the site, wear proper clothes and personal safety protection articles.
9.1.2 In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Then investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning shall obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.1.4 All professional shall be on respective duties during the whole commissioning to guarantee
the safe operation of equipments.
9.2 Personal Risk and Preventative Measures
9.2.1 Rotating equipment
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 24 of 30

Injuries might be caused by rotating equipment during commissioning or test. Therefore,


special care must be taken during work and do not touch the rotating components with tools
or your hand.
9.3 Equipment Risk and Preventative Measures
9.3.1 Emphasis shall be put on the monitoring of bearing temperature, bearing bush vibration, and
motor coil temperature during test run of auxiliary equipment to avoid temperature and
vibration exceeding the allowable limit. Stop the operation of equipment as necessary.
9.3.2 Before opening the feed valve of ash discharging pump of the ash silo, the sundries within the
buckets and the feed pipe must be removed manually to avoid entering the storage pump
causing clogging of the gasification holes of the pump and seizing the feed and discharge
valves.
9.3.3 Check the ash silo and remove the inside sundries to guarantee that the fluidizing holes of the
fluidizing plate are not blocked.
9.3.4 Check the deslagging system before commissioning to guarantee there are no large sized
sundries causing damage to equipment.

10. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-015-2009A Page 25 of 30

10.1 Appendix 1 Commissioning Condition Checklist

No. Items Requirements Result Verifie Rem


d by arks
Erection work of system
1 All fulfilled □Yes □No
and its equipment

2 Foreign materials inside the Clean up □Yes □No


system and its equipment

Test operation for each Eight-hour test operation


3 equipment separately finished and all defects □Yes □No
eliminated.

4 Ventilation test Test finished and defects □Yes □No


eliminated.

5 Ash silo dried by ventilation Forty eight-hour □Yes □No


aeration-drying finished.
Checking of
6 pneumatic and hand The indication conforms to □Yes □No
-operated valves by operating the real position.
(opening / closing)
Purged by air
7 All ash conveying pipelines □Yes □No
pressure test.
Thermodynamic instrument, Commissioning is
8 level gauges, pressure finished, can be put into □Yes □No
switches, etc. operation

9 All safety valves of the system Completely equipped and □Yes □No
calibrated for satisfaction.
Commissioning finished
10 Programmed control system and have a correct logic □Yes □No
relationship.
Commissioning
11 Interlock and audio & visual finished and tested □Yes □No
alarm device
for satisfaction.
Clear road,
12 Field condition □Yes □No
sufficiency of illumination.

13 Communication equipment Sufficient for use and □Yes □No


performance is reliable.

14 Fire apparatus Sufficient in quantity and □Yes □No


easy for use

15 Overhaul tools and materials All categories with □Yes □No


sufficient quantities.

16 Tools and instrument for Prepared □Yes □No


commissioning

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning Procedure
SCCTI-TS-GL-CS-015-2009A Page 26 of 30

10.2 Appendix2 Valves Commissioning Record


Valves Commissioning Record C

Remote Operating time


KKS code Name Local position Date Result Signat Remarks
indication Directi Feed On Off(Clos ure
on back (Open) e)

10ETG11AA701 FIRST FIELD NO.1 CONVEYER HOPPER


INTAKE VALVE

10ETG12AA701 FIRST FIELD NO.2 CONVEYER HOPPER


INTAKE VALVE

10ETG13AA701 FIRST FIELD NO.3 CONVEYER HOPPER


INTAKE VALVE

10ETG14AA701 FIRST FIELD NO.4 CONVEYER HOPPER


INTAKE VALVE

FIRST FIELD NO.1 CONVEYER HOPPER


10ETG10AA701 TRANSPORTATION INFLOW VALVE
OPEN COMMAND

10ETG12AA701 SECOND FIELD NO.1 CONVEYER


HOPPER INTAKE VALVE

10ETG22AA701 SECOND FIELD NO.2 CONVEYER


HOPPER INTAKE VALVE

10ETG23AA701 SECOND FIELD NO.3 CONVEYER


HOPPER INTAKE VALVE
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning Procedure
SCCTI-TS-GL-CS-015-2009A Page 27 of 30

10ETG24AA701 SECOND FIELD NO.4 CONVEYER


HOPPER INTAKE VALVE

SECOND FIELD NO.1 CONVEYER


10ETG20AA701 HOPPER TRANSPORTATION INFLOW
VALVE

10ETG31AA701 THIRD FIELD NO.1 CONVEYER HOPPER


INTAKE VALVE

10ETG32AA701 THIRD FIELD NO.2 CONVEYER HOPPER


INTAKE VALVE

10ETG33AA701 THIRD FIELD NO.3 CONVEYER HOPPER


INTAKE VALVE

10ETG34AA701 THIRD FIELD NO.4 CONVEYER HOPPER


INTAKE VALVE

THIRD FIELD NO.1 CONVEYER HOPPER


TRANSPORTATION INFLOW VALVE
10ETG30AA701 OPEN COMMAND

10ETG41AA701 FOUR FIELD NO.1 CONVEYER HOPPER


INTAKE VALVE

10ETG42AA701 FOUR FIELD NO.2 CONVEYER HOPPER


INTAKE VALVE

10ETG43AA701 FOUR FIELD NO.3 CONVEYER HOPPER


INTAKE VALVE
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning Procedure
SCCTI-TS-GL-CS-015-2009A Page 28 of 30

10ETG44AA701 FOUR FIELD NO.4 CONVEYER HOPPER


INTAKE VALVE

10ETG40AA701 FOUR FIELD NO.1 CONVEYER HOPPER


TRANSPORTATION INFLOW VALVE

10ETG20GC001 SECOND FIELD PIPE OUTFLOW


VALVE

10ETG20GC002 THIRD FIELD PIPE OUTFLOW


VALVE

10ETG60AA002 GASIFICATION FAN NO.1 OUTLET


VALVE

10ETG60AA004 GASIFICATION FAN NO.2 OUTLET


VALVE

10ETG20AA007 TOP OF FLY ASH SILO SWITCH VALVE


TO 2# FLY ASH SILO VALVE 1

10ETG10AA007 TOP OF FLY ASH SILO SWITCH VALVE


TO 1# FLY ASH SILO VALVE 2

10ETG10AA008 TOP OF FLY ASH SILO SWITCH VALVE


TO 2# FLY ASH SILO VALVE 2

00ETP10AA002 1# SCREW AIR COMPRESSOR OUTLET


VALVE

00ETP10AA010 1# REFRIGERATED AIR DRYER INLET


VALVE
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning Procedure
SCCTI-TS-GL-CS-015-2009A Page 29 of 30

00ETP10AA011 1# REFRIGERATED AIR DRYER OUTLET


VALVE

00ETP10AA005 2# SCREW AIR COMPRESSOR OUTLET


VALVE

00ETP10AA015 2# REFRIGERATED AIR DRYER INLET


VALVE

00ETP10AA016 2# REFRIGERATED AIR DRYER OUTLET


VALVE

00ETP10AA008 3# SCREW AIR COMPRESSOR OUTLET


VALVE

00ETP10AA020 3# REFRIGERATED AIR DRYER INLET


VALVE

00ETP10AA021 3# REFRIGERATED AIR DRYER OUTLET


VALVE

10ETG51AA001 ECONOMIZER NO.1 CONVEYER


HOPPER INTAKE VALVE

10ETG52AA001 ECONOMIZER NO.2 CONVEYER


HOPPER INTAKE VALVE

10ETG53AA001 ECONOMIZER NO.3 CONVEYER


HOPPER INTAKE VALVE

10ETG54AA001 ECONOMIZER NO.4 CONVEYER


HOPPER INTAKE VALVE
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Ash Removal and Deslagging System REV A
Commissioning Procedure
SCCTI-TS-GL-CS-015-2009A Page 30 of 30

ECONOMIZER NO.1 CONVEYER


10ETG50AA001 HOPPER TRANSPORTATION INFLOW
VALVE

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-LB-001

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI

CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power Commissioning & PLTU 1 Jatim-Pacitan (2×315MW)
DESIGN STAGE
Test Institute Project

Approval Check
Procedure of Boiler Steam Blowing
Review Design
Date Scale N/A DWG No. SCCTI-TS-GL-CS-016-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 2 of 55

Table of Contents

1. PURPOSE .................................................................................................................................... 3
2. SCOPE ......................................................................................................................................... 3
3. PREPARATION BASIS............................................................................................................... 3
4. GENERAL DESCRIPTION OF SYSTEM AND EQUIPMENT ................................................ 3
5. TOOLS, INSTRUMENT FOR COMMISSIONING ................................................................... 4
6. PREREQUISITE FOR COMMISSIONING ............................................................................... 4
7. MEASURES FOR COMMISSIONING ORGANIZATION ..................................................... 10
8. BLOWING FLOW..................................................................................................................... 12
9. BLOWING PARAMETERS AND THE QUALIFIED STANDARD ....................................... 12
10. TEMPORARY FACILITY FOR BLOWING ............................................................................ 14
11. PREPARATION PRIOR TO IGNITION ................................................................................... 15
12. TEMPERATURE RISING AND PRESSURE RISING FOR BOILER IGNITION.................. 25
14. SAFETY MEASURES .............................................................................................................. 31
15. APPENDIX................................................................................................................................ 36
Appendix 1 Blowng condition checklist.......................................................................................... 37
Appendix 2 Record list for blowing acceptance............................................................................. 45
Appendix 3 Record Table for Blowing Parameters ....................................................................... 46
Appendix 4 Blowing Diagram ......................................................................................................... 47
Appendix 5 Blowing Diagram for Desuperheating water Pipeline of SuperHeater or Reheater
............................................................................................................................................................... 48
Appendix 6 Processing Diagram of Grain Collector ..................................................................... 49
Appendix 7 Checklist for Motorized Valve of Steam-Water System............................................ 50
Appendix 8 Checklist for Control Valve of Steam-Water System ................................................ 55
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 3 of 55

1. Purpose
The procedure of boiler steam blowing will be employed to blow away the foreign matters
remained in the such systems as the boiler superheater, reheater and steam pipeline to ensure
the safe and economic operation of the unit.

2. Scope
This procedure is applicable for the commissioning of steam blowing of the unit, the blowing
scope covers:
2.1 The boiler superheater system and the main steam pipeline;
2.2 The boiler superheater system, the reheating pipeline at cold section and the reheating
pipeline at hot section;
2.3 The main steam desuperheating water pipe and desuperheating water pipeline for the reheater
2.4 The high pressure bypass pipeline of steam turbine
2.5 The gas source for the shaft seal of steam turbine and other pipelines at the steam turbine side

3. Preparation Basis
3.1 The diagram for boiler burning and coal pulverizing system;
3.2 The thermodynamic system diagram for the whole boiler plant;
3.3 Boiler Product Manual;
3.4 Manual for Boiler Installation
3.5 Manual for Boiler Operation

4. General Description of System and Equipment


4.1 The model of boiler: DG1025/18.3-II13, natural circulation brown coal-fired drum boilers
with single tangentially fired furnace (at four-corner), Type II arrangement in open air, reheat
system and balanced draft.
4.2 Temperature regulating mode: the water spray desuperheating is employed for the
superheating steam, swaying of the burner nozzle is taken as the principal for the reheating
steam and micro regulating by water spray is assisted.
4.3 The model of the coal mill is HP963; five coal mills are provided for each boiler (when the
coal is designed for burning, four operating and one standby).
4.4 The arrangement and type for the burner: four-corner arrangement is employed; the centerline
of the four-corner mounted burner is tangent with two imaginary circles the centerline of the
furnace respectively; the diameters for two imaginary circles are ф548mm and ф1032mm
respectively.
4.5 Main parameters of the boiler:

Unit BMCR TMCR TRL 75%TRL 50%TRL


927.8
Flow T/h 1025 976.19 678.00 467.50
0
Main
steam Pressure MPa 18.0 17.5 17.33 14.33 9.56
Temperature ℃ 541 541 541 541 535
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 4 of 55

766.0
Flow T/h 863.7 802.023 571.00 402.08
1
Inlet pressure MPa 3.99 3. 625 3.54 2.66 1.85
Outlet
Reheat MPa 3.80 3.438 3.38 2.53 1.76
pressure
steam
Inlet
℃ 329 322 320 313 318
temperature
Outlet
℃ 541 541 541 541 515
temperature
Temp. of feed water ℃ 281 275.5 273 255 234

5. Tools, Instrument for Commissioning


5.1 Walkie-alkie;

5.2 Handheld vibration meter;

5.3 Temperature measurement meter;

5.4 Pressure gauge。

6. Prerequisite for Commissioning


Prior to system commissioning, the commissioning personnel shall perform complete
inspection upon the prerequisite for system commissioning according to Appendix 1
(Commissioning Condition Checklist) and enter the result of check on records accordingly.
6.1 Conditions that must be available with machinery provisions
6.1.1 Temporary pipeline system for blowing
(1) Completion on installation and heat insulation of the temporary pipeline (including such
work as drainage and heat insulation);
(2) Completion on installation and commissinoing for the temporary motorized valve,
bypass valve and drainage valve;
(3) Completion on fabrication and installation for target device, with sufficient target;
(4) Being qualified for on/off test of the motorized valve and the test for the lighting and
signal
(5) Completion and qualification on installation of the counter-force support and fixing and
sliding hanger for the temporary pipeline;
(6) Completion on fabrication and installation of the grain collector;
(7) Completion on installation and calibration for the pressure gauge and thermometer
installed for the temporary system of blowing.
6.1.2 Flue-gas and air system
(1) The air pressure test of boiler is completed and qualified through acceptance.
(2) Completion on installation and heat insulation for boiler proper as well as flue-gas and
air duct
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 5 of 55

(3) Completion on single commissioning for IDF, FDF, primary fan and air preheater and
commissioning of subsystem;
(4) Completion and qualification on inspection and adjusting for each damper and baffle
6.1.3 Flame detecting system
(1) Completion on single commissioning of the cooling fan and interlock protection test as
well as qualification on acceptance
(2) Qualification on static commissioning for flame scanner;
(3) The commissioning of the CCTV system is complete and it can be put into operation at
any time.
(4) Qualification on commissioning for the flue-gas temperature probe of the boiler;
6.1.4 Electrostatic precipitator system
(1) Completion on installation and heat insulation for electrostatic precipitator as well as
qualification on acceptance;
(2) Qualification on air distribution test as well as pressure rising and vibration test for the
electrostatic precipitator
(3) Completion on installation for heating device of dust hopper for the electrostatic
precipitator and qualification on inspection and acceptance
6.1.5 Fuel oil system
(1) Completion on installation and heat insulation for oil storage and boiler fuel oil system
and completion on single commissioning;
(2) Completion on water pressure test for the boiler fuel oil system and qualification on
being flushed by water and being blown by steam;
(3) Completion on installation and blowing for steam blowing pipeline of fuel oil system as
well as completion on commissioning for each blow down valve
(4) Completion on commissioning for each motorized and pneumatic valve of fuel oil
system as well as qualification on acceptance;
(5) Qualification on simulation test for each interlock protection (MFT and OFT) of fuel oil
system;
(6) Completion on extending and withdrawing test for each oil gun and high-energy igniter;
(7) Completion on static commissioning for each flame check
6.1.6 Boiler proper
(1) Completion on installation and heat insulation for boiler proper as well as qualification
on acceptance;
(2) Completion on water pressure test of boiler and qualification on acceptance;
(3) Completion on installation and heat insulation for such systems as drainage, air vent,
regular discharging, continuous discharging, bottom heating and nitrogen charge and
completion on commissioning for each motorized valve as well as qualification on
acceptance;
(4) Installation for water pressure block plate of the main steam pipeline at oulet of the
superheater is completed to be applicable for the water pressure prior to ignition of
boiler;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 6 of 55

(5) After the water pressure test, the valve cores of water pressure for each safety valve of
drum and superheater are removed to restore to formal conditions and meet the
requirement of manufacturer. The water pressure block plate of steam and water system
should be removed.
(6) The spring hangers for each steam and water pipeline are complete and perfect and pins
are removed so that they are in conditions of free-bearing capacity.
(7) Qualification on commissioning for the motorized and pneumatic valve for each steam
and water pipeline;
(8) The parties inspect expansion system for boiler proper jointly to conform that there is
free of barrier and expansion; each expansive indicators should be complete and be
adjusted to zero;
(9) The ladders, platforms and the handrails of the boiler proper should be complete, the
illumination should be sufficient; the boiler proper should be clean;
(10) After completion of pickling for the boiler, the inner of drum should be clean, the inner
devices should be returned to normal, the drum should be sealed, the temporary
facilities should be removed and the formal system has been restored.
(11) The water level gauge of the drum should be installed properly; the commissioning for
water level through CCTV system is completed and can be put into operation at any
time.
(12) The sampling and dosing devices for the boiler water are installed properly and
qualified through inspection.
(13) The installation and heat insulation work for water supply, desuperheating water and
the emergency water spray system are completed; they are qualified through water
washing; the commissioning for the motorized and pneumatic valves is completed. The
installation and heat insulation for the temporary back-washing pipeline of the
desuperheater are completed; the qualification is made via inspection and
confirmation.
(14) Each manhole door and inspection hole door for the boil body should be complete and
sealed.
(15) The cold inspection for installation of the boiler burner and the cold commissioning for
coal flame check are qualified as well as are ready for use.
6.1.7 Deashing system
(1) The installation for the slag pit at the bottom of boiler (including the wind seal at the
bottom of boiler), slag depot and the rotary equipment is completed and is qualified
through acceptance.
(2) The commissioning for each single equipment of deslagging system is completed, the
on/off test for the hydraulic shut-off valve is qualified and they are ready for use.
(3) The installation and commissioning for dedusting system equipment are completed; the
commissioning for dedusting programmed logic is completed; they are ready for use.
6.1.8 Coal handling system
(1) Completion on equipment installing and commissioning for each single equipment as
well as qualification on acceptance
(2) Qualification on interlock protection test of system
(3) The defects found during the system commissioning are removed, the coaling condition
is provided.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 7 of 55

6.1.9 Soot blower system


(1) Completion on installation and heat insulation for boiler proper, soot blower of
convection funnel and pipeline;
(2) Completion on installation and commissioning for the motorized and pneumatic valve
on the pipeline for the steam source of soot blower;
(3) After completion for soot blowing operation test of air preheater, it can be put into use at
any time.
6.1.10 Coal pulverizing system
(1) Completion on installation of coal pulverizing system and heat insulation
(2) Qualification on trial run of the seal fan;
(3) Qualification on primary air leveling for pulverizing system;
(4) Qualification on calibration of airflow at the inlet of coal mill;
(5) Completion on commissioning for lubrication system of coal mill;
(6) The commissioning for coal mill and coal feeder is completed; the operation condition is
provided;
(7) Completion on transmission test for all the baffles and dampers
(8) Qualification on calibration for weighing device of coal feeder
6.1.11 Air heater system
(1) Completion on installation and heat insulation
(2) The single commissioning is completed and it is ready for use;
(3) Qualification on interlock protection test for system
6.1.12 Compressed air system
(1) Completion on single and sub-system commissioning for instrument and service air
compressors;
(2) Completion on installation for instrument and service air tanks and qualification on
calibration of safety valve;
(3) Qualification on blowing for instrument and service air pipelines;
(4) Qualification on interlock protection test for system
6.1.13 Fire fighting system
(1) Completion on installation of firefighting system
(2) Completion on each firefighting facility and qualification on water draining test and
being standby state
(3) Completion on the firefighting appliances in the control room, electric room and fuel oil
system
61.14 Industrial water system
(1) Completion on installation of industrial water system and qualification on water pressure
test
(2) After the trial run for the industrial pump and the industrial water subsystem is
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 8 of 55

completed, the operation can be made at any time.


6.1.15 Auxiliary steam system
(1) After the installation and commissioning for the boiler are completed, it can be put into
service.
(2) Completion on installation and heat insulation for each auxiliary steam system
(3) After the qualification for the motorized valve for the auxiliary system is confirmed, the
operation can be made.
6.1.16 Isolation between relevant utilities and 2# unit
6.1.17 Chemical water preparation system
(1) The chemical water system is provided with the condition of continuous water supply.
(2) Completion on trial run for water charging system
6.1.18 Requirement for steam turbine discipline
(1) The condenser and hot water well are qualified through cleaning; the condensing pump
is qualified through trial run; the system is qualified through flushing; the water supply
can be made towards the deaerator;
(2) After the inner of the deaerator is clean and flushed with water and the steam heating
pipeline is blown, it resumes to normal conditions and the heating and the operating
conditions are provided;
(3) The trial run for the electric feed water pump is qualified; the feed pipeline is qualified
by flushing of the entire system; it resumes to normal conditions and has ready for
normal operation. ;
(4) Various measures to prevent steam from entering the turbine have been taken and the
qualification of acceptance has been made through inspection;
(5) The commissioning work for the vacuum system of steam turbine is completed and the
normal operation conditions are provided;
(6) The commissioning work for lubrication oil, sealing oil and jacking oil system for the
steam turbine is completed; the turning system is ready for normal operation;
(7) The main steam pipeline of steam turbine, reheating system and the high and low
pressure bypass drain valve are confirmed to be qualified and can be put into
operation;
(8) After commissioning and inspection for the temperature measuring points of the steam
turbine cylinder are completed, the temperature of the cylinder can be shown correctly;
(9) Each electric steam extraction interception valve is confirmed to be qualified and
closed strictly;
(10) The drainage for each condenser introduced is isolated reliably;
(11) The spray for low-pressure cylinder can be put into operation.
6.2 Conditions that must be available with electrical and I&C
(1) The static test for boiler FSSS (fuel oil and coal feeding part) is completed, including:
1) Completion on interlock test for flame check cooling fan;
2) Completion on inspection and test for blowing condition of furance;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 9 of 55

3) Completion on MFT test and the interlock test after MFT;


4) Completion on OFT test of fuel oil and the interlock test after OFT;
5) Completion on fuel oil leakage test;
6) Completion on combustion management system for each oil gun;
7) Completion on control and interlock test for coal feeder and coal mill;
(2) Completion on sequence control, interlock and protection test (SCS part) of auxiliaries,
including:
1) Start conditions, trip conditions, programmed start and programmed stop for air
preheater ( A/B);
2) Start conditions, trip conditions, programmed start and programmed stop for
induced air fan (A/B);
3) Start conditions, trip conditions, programmed start and programmed stop for forced
draft fan (A/B);
4) Start conditions, tripping conditions, programmed start and programmed stop for
primary air fan (A/B);
5) Start conditions, trip conditions, programmed start and programmed stop for
primary air fan (A/B/C/D/E);
6) Start conditions, trip conditions, programmed start and programmed stop for coal
feeder (A/B/C/D/E);
7) Start conditions, trip conditions for sealing fan (A/B);
(3) The static test for DAS system is completed; the installation for the temperature
measuring points of each metal wall of heating face for boiler is completed and
qualification is made through cold state inspection and acceptance as well as the original
record has been made by the professionals; the project commissioning work related to
DAS system and blowing work is completed, with accurate and reliable indication, such
as: pressure of drum, superheater, reheater, steam temperature, wall temperature, water
supply pressure, temperature, water supply flow, electric contact water level gauge,
furnace flame CCTV, negative pressure meter of furnace, flue-gas temperature probe of
furnace, secondary air, air flow of primary air, air pressure and temperature, steam water
and the flue-gas and air system as well as other measuring points of all I&Cs, fuel
pressure, fuel temperature, air flow meter, current of each auxiliary device, temperature
of bearing and vibration of bearing. All above must be put into operation properly.
(4) The commissioning and transmission for various protection, alarm and acoustic and light
signals of alarm window are completed and the normal alarm can be made.
(5) The safety power supply is ready for use.
(6) The two- way power supply for DCS can be put into service normally.
(7) The control chart for the steam blowing system of unit is drawn from DCS. DAS system
is used for the data acquisition during blowing; prior to ignition of boiler, such works as
the system connection, parameters configuration and print commissioning are completed
according to the parameters listed in the table below.

Drum pressure Pressure ucpstream of grain collector

Pressure for superheated steam Temperature upstream of grain collector


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 10 of 55

Inlet pressure for reheated steam Pressure downstream of grain collector

Outlet pressure for reheated steam Exhaust steam pressure for the temporary pipe

Temperature of superheated steam Exhaust steam temperature for the temporary


pipe

Reheat steam temperature Feed water flow

6.3 Conditions that must be available with civil construction


(1) The roads within the commissioning site must be free of obstructions. There is adequate
lighting and reliable emergency illumination。
(2) The communication equipments on the commissioning site are convenient and available
to guarantee the communication is smooth. There are sufficient fire fighting appliances.
(3) After the air conditioning system is debugged properly, it can be put into operation to
meet the requirement of computer equipments.
(4) After the installation and commissioning for the elevator of boiler is completed and
qualified via acceptance, it can be put into use.
6.4 Other conditions required
(1) The joint inspection is organized for such related aspects as the construction, building,
Owner, production and commissioning and the problems found should be solved
completely. The ignition condition is confirmed to be provided.
(2) The preparation for the production commissioning is completed and the operators are
provided in completeness and qualified via the training and examination. The operation
regulation and the system diagram are reviewed; the operation tools are prepared
reasonably and the operation log is prepared properly.
(3) The chemicals and materials for commissioning are prepared properly; the sufficient
chemical water, fuel and fire coal in compliance with the design requirement should be
prepared.
(4) The maintenance tools and materials required are prepared.
(5) The command and organizing system for trial run is perfect and the division of work is
defined clearly.

7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows:
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;

◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 11 of 55

◆ Hold technical disclosure meeting for commissioning;

◆ Organize the commissioning work to be carried out by various parties;

◆ Give instructions to operators in the operation;

◆ Prepare commissioning report.


7.2 Responsibilities of Installation Contractor
◆ Be responsible for individual commissioning of equipment and provide relevant record
and certificate of commissioning;
◆ Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;

◆ Be responsible for temporary coordination of local control and instruments and


connection terminals.;
◆ Be responsible for the fabrication and installation for target board and grain collector;

◆ Be responsible for the isolation work and the temporary listing work for relevant
systems and equipments
7.3 Responsibilities of Equipment Manufacturers
◆ Representative of manufacturer, if present on the site offering service, shall provide
technical assistance during equipment commissioning.
7.4 Responsibilities of Operation Department
◆ Prepare tools to be involved in operation;

◆ Prepare operation log and forms;

◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;
◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;
◆ Be responsible for dealing with the accidents occurred in commissioning。
7.5 Responsibilities of Dongfang Electric Corporation
◆ Be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning。


7.6 Responsibilities of Project Owner
◆ Supervise the execution of commissioning procedures;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 12 of 55

◆ Witness the commissioning work;

◆ Accept the results of commissioning。

8. Blowing flow
8.1 The blowing flow for the boiler superheater, main steam pipeline, reheater and reheating
pipeline at the hot and cold section is as follows:
Drum--->superheater---> main pipeline of the main steam pipe---> branch pipeline of the
main steam pipe---> main steam valve (adding the block plate) --->leading out of temporary
branch pipe---> motorized valve for temporary blowing control --->temporary pipe--->
reheating pipeline at cold section (adding the grain collector at the boiler side) ---> reheater
---> reheating pipeline at hot section ---> branch pipe in front of combined intermediate
valve---> combined intermediate valve (added with the block plate) ---> leading out of
temporary branch pipe---> temporary pipe ---> target board machine ---> temporary pipe --->
to atmosphere via muffle
8.2 The blowing flow for HP bypass system is as follows:
Drum--->superheater---> main pipeline of the main steam pipe---> HP bypass pipeline--->
motorized valve for temporary control of HP bypass blowing ---> HP bypass pipeline
--->reheating pipeline at cold section (adding the grain collector) ---> reheater ---> reheating
pipeline at hot section ---> branch pipe in front of combined intermediate valve---> combined
intermediate valve (added with the block plate) ---> leading out of temporary branch pipe--->
temporary pipe ---> target board machine ---> temporary pipe ---> to atmosphere via muffle
8.3 Blowing flow for desuperheating water system of superheater and reheater (with
reference to Appendix):
The flow-measuring device for the first, second and third stage desuperheating water system
of superheater is not installed temporarily, which is disconnected at the location of control
valve (removal of the control valve) and led out by employing the temporary pipeline
respectively to perform blowing and flushing with the steam and water supply for at steam
side and water side. The blowing pressure at steam side of the superheater is around
3.0MPa(Blowing for 5 times and 5 minutes once). The waterside flushing can be performed
after the water supply pump is started until clear water is drained through blowing. The
reheater steam side is blown with the main steam system simultaneously.
8.4 Blowing flow for the main steam system of feedwater pump turbine is as follows:
Drum--->superheater---> main steam pipeline---> HP main steam valve of feedwater pump
turbine---> temporary pipe blowing ---> steam exhaust (blowing completion for steam
turbine)
8.5 Blowing for the steam source for the steam turbine shaft seal and other pipeline at the
steam turbine side:
The content refers to the blowing commissioning procedure at the steam turbine side. The
boiler of this project is completed in combination with the steam turbine.

9. Blowing parameters and the qualified standard


9.1 Blowing parameters:
The pressure of drum is 5.5~ 6.5MPa and the temperature of main steam is 350℃~450℃ for
the blowing of the main pipeline (the specific parameters are determined in conformity with
the blowing coefficients from calculation during the process of the actual blowing). The
temporary control valve should be opened and the temporary control valve should be closed at
the 3.8~ 4.5Mpa of drum pressure. When the control valves are closed fully, the temperature
reduction for the saturation temperature of drum is not greater than 42℃.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 13 of 55

The blowing parameters are determined as follows according to the blowing coefficient
greater than 1.0:
When the temporary control valve is open, refer to the table below for pressure of drum:
pressure of drum (MPa)

System Description Trail blowing Formal blowing Target

Main reheating steam system 3.0 3.5 4.0 6.0 6.0

High pressure bypass system 3.0 4.0 -

Steam system for


miscellaneous for steam
2.0 3.0 3.0
turbine and feedwater pump
turbine

Steam temperature:for formal blowing, the temperature is 380~ 450℃; for trail blowing, the
temperature is above 350℃, the exhaust steam temperature is above 180℃.
When the temporary control valve is closed, refers to the table below for pressure of drum:
pressure of drum (MPa)

Pressure of drum at the time of starting Pressure of drum at the time of closing
(MPa) (MPa)
3.0 1.6
3.5 1.8
4.0 2.1
4.5 2.4
5.0 3.5
5.5 3.8
6.0 4.0
6.5 4.2

9.2 Criteria of acceptance:


Under the condition that the blowing coefficient is greater than 1, the maximal grain diameter
with the spot impacted on the target board is not greater than 0.5mm, in addition, when the
number of visible spots ( 0.2~0.5mm) is not more than 5, twice continuous blowing are
deemed as to be qualified. What’s more, the number of spots for the second target board
should be less than that of the first. The inspection target board is copper board or the
aluminum board.
The calculation formula for the blowing coefficient is as follows:
Steam flow at blowing 2×steam specific volume at blowing
Steam flow under rated load2×steam specific volume under rated load
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10. Temporary facility for blowing


10.1 The special -purpose block plate provided by the manufacturer of the steam turbine will be
used to isolate the HP main steam valve from leading to the steam turbine side and led out
temporary pipe from the valve cap and the temporary control motorized valve is added. The
temporary pipeline is unblocked with the reheating pipeline of cold section at downstream of
HP exhaust check valve (If the HP exhaust check valve is not installed, this position is
disconnected.)
10.2 The treatment for the intermediate pressure main steam valve is identical to the one of the
high-pressure main steam valve.
10.3 The high-pressure bypass valve is not installed; the temporary electric check valve is installed
additionally to control blowing.
10.4 The low-pressure bypass valve is disconnected before entering into the condenser, the original
valve is not installed, and the temporary pipe is led to the main exhaust steam pipe or the
low-pressure bypass valve is not purged, the manual clearing mode is employed for the
installation.
10.5 At the straight pipe section of the main exhaust pipe, the target board device is installed
additionally.
10.6 The muffler is added at the exhaust, the installation for the muffler refers to the installation of
muffler from the manufacturer as well as the operation and maintenance manual. The
resistance pressure of muffler is not greater than 0.2MPa.
10.7 The flow device within the scope of blowing is not installed and connected with the short pipe
with identical materials and pipe diameter.
10.8 For the temporary pipe purged, except for the pipeline from the target device of the main
exhaust pipe to the muffler, the full bottoming with the argon arc welding is made. The sand
blasting treatment is made prior to the installation of temporary pipe. The inner of the entire
pipe should be clean and inspected by the quality control personnel.
10.9 When blowing the temporary pipe, the secure and reliable supports and hangers should be
installed; and the heat expansion of pipeline and the airflow counter-force for blowing should
be taken into account.
10.10 The temporary heat insulation is required to be made for the temporary pipe purged.
10.11 At each lowest point for the temporary blowing system, the drain pipeline and the drain valve
are installed; the drainage is drained up to the safety place.
10.12 Such drain pipelines as the main steam, reheat steam (at cold and hot section) and HP and LP
bypass pipelines are disconnected with the drain flash tank and the temporary special-purpose
drainpipe is connected to discharge to atmosphere.
10.13 The temporary control valve for blowing should be maintained properly and provided with the
stop function at the intermediate random position. The operation switch for the temporary
valve should be led to the appropriate location of the concentrated control room. In order to
heat the pipe and protect the temporary valve, the temporary valve should be provided with
the bypass valve (PN>10Mpa, DN=89,t>450℃).
10.14 On the cold section pipe at inlet of the reheater, the grain collector should be added in parallel;
at front and back of grain collector, a pressure gauge with 0~2.5MPa should be installed
respectively.
Requirement for the technical parameters of the grain collector:
(1) The pressure is greater than 3.0MPa; the temperature is greater than 450℃;
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Commissioning
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(2) Refers to the attached diagram for the constructional diagram.


10.15 Requirement for the technical parameters of the motorized valve controlled temporarily:
(1) Dg=300、Pg≥16.0MPa, T>450℃;
(2) Fully open/close time should be less than 60 seconds uniformly;
(3) It can be stopped at the intermediate random location
(4) Welding the single- gate valve
10.16 Selection principles for the temporary pipeline
10.16.1 The cross section of the temporary pipeline should be greater than or equal to the one of the
upstream pipeline.
10.16.2 Selection of the wall thickness:
(1) The design pressure for the temporary pipeline at the upstream of temporary control
valve is P>10.0Mpa and t≥450℃;
(2) The design pressure for the temporary pipeline from the downstream of the temporary
control valve to the HP exhaust check valve is P>4.0Mpa and t≥450℃;
(3) The design pressure for the temporary pipeline from the intermediate united valve to the
exhaust steam pipe is P>1.6 Mpa and t≥450℃;

(4) Design pressure for the main exhaust pipe is P>1.5Mpa and t≥450℃。
10.17 Specification for the target:
(1) Material: aluminum
(2) Length: inner diameter for the longitudinal running through pipeline;
(3) Width: 8% of length;
(4) Thickness: 7mm;

(5) Quantity:60 pieces。


Requirement for processing: the grinding and polishing treatment must be conducted for the
surface of the entire targets.
10.18 On the temporary pipe near the exhaust, a piece of pressure meter with 0~0.6MPa and a piece
of thermometer with 0~500℃ are installed and introduced into DCS system.
10.19 The mechanical treatment for the pipelines that cannot be participated into blowing should be
executed, such as the steam lead pipe of the steam turbine or the LP bypass pipeline.
10.20 After blowing is completed, the pipeline is restored and the reliable measures must be taken
for avoiding the secondary pollution.

11. Preparation prior to ignition


11.1 Cold state inspection and transmission for the valve
11.1.1 Inspect and accept the electric or pneumatic switch valve as well as record the data below:
Inspect whether KKS code, designation, local position indications, remote operation direction
(as well as feedback are correct; the time for valve on/off, test date and signature of person in
charge of test. Refer to Appendix 7 for other contents.
11.1.2 Inspect and accept the electric or pneumatic control valve as well as record the data below:
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Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 16 of 55

Inspect whether KKS code, designation, local position indications and feedback indications
corresponding to upward command of 0%, 50%, 75%, and 100% and downward command of
100%, 75%, 50%, and 0% respectively, test date, signature of person in charge of test. Refer
to Appendix 8 for other contents..
11.2 Inspection for interlock protection and alarm (note: the interlock protection test is based on
the result of discussion on logical.)
11.2.1 The device power supply shall be located at the test location to inspect the items below:
(1) Start equipment through the computer and feedback on the computer is correct;
(2) Stop equipment through the computer and feedback on the computer is correct;
(3) Emergency button operates reliably
11.2.2 The interlock protection test for the boiler MFT (OFT) refers to the relevant contents in the
whole set of commissioning procedure and fuel commissioning procedure.
11.2.3 The interlock protection test for the pulverizing system refers to the relevant contents in the
commissioning procedure of pulverizing system.
11.2.4 The interlock protection test for the steam and water system covers:

Fixed Result
No. Test item Remarks
value s
1#and 2# recirculation motorized valves for boiler economizer
After 2# recirculating motorized valve is closed , 1#
(1) recirculation motorized valve is closed by means of
interlock
After 2# recirculating motorized valve is opened , 1#
(2)
recirculating motorized valve is by means of interlock
Boiler Steam pressure protection test
When the steam pressure of the steam header is
greater than 18.07Mpa, the ERV electromagnetic
(1)
pressure release valve is opened automatically to
relieve the pressure
When the steam pressure of the steam header is less
(2) than 17.6Mpa, the ERV electromagnetic pressure
release valve shall close automatically.
Boiler superheated steam header starting the1#and 2# exhaust motorized valve
After 2# exhaust motorized valve is closed , 1#
(1) exhaust motorized valve is closed by means of
interlock
After 2# exhaust motorized valve is opened , 1#
(2) exhaust motorized valve is opened by means of
interlock
Boiler reheated steam header starting 1# and 2# exhaust motorized valve,
After 2# exhaust motorized valve is closed , 1#
(1) exhaust motorized valve is closed by means of
interlock

(2) After 2# exhaust motorized valve is opened , 1#


exhaust motorized valve is opened by means of
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interlock
Open/close conditions on the continuous blow down motorized valve and continuous blowdown
control valve
After opening the continue blowdown motorized
(1) valve, the manual control is allowed to open the
control valve
After closing the continuous blowdown control valve,
the interlock –close is performed or the manual
(2)
control is allowed to close the continuous blowdown
motorized valve
1# and 2# emergency drain motorized valves for boiler (setting the interlock operation switch)
The 1# and 2# emergency drain motorized valve shall
be closed by means of interlocking when the drum
(1)
level falls to below 100MM; high water-level alarm
should be performed.
The 1# and 2# emergency drain motorized valve shall
be opened by means of interlocking when the drum
(2)
level reaches 150MM; high water-level alarm should
be performed.
Interlock conditions for desuperheating water motorized valve and control valve
When MFT motion or load is less than 20%, the main
motorized valve and motorized sub-valve of
overheating system desuperheating water shall be
(1) closed by means of interlocking, and all
desuperheating water control valves shall be
automatically transformed into manual operation and
closed by means of interlocking.
When the first stage desuperheating water control
valve for superheater is closed (<5%) or MFT motion
(2) or load is less than 20%, interlock-close the
corresponding motorized sub-valve of the superheater
desuperheating water.
When the first stage desuperheating water control
valve of superheater is opened (>5%), interlock-open
(3)
the corresponding motorized sub-valve of the
superheater desuperheating water..
When the second stage desuperheating water control
valve at A side of the superheater is closed(<5%) or
(4) MFT motion or load is less than 20%, close the
corresponding motorized sub-valve of the superheater
desuperheating water by means of interlocking
When the second stage desuperheating water control
valve at A side of the superheater is opened(>5%),
(5) open the corresponding motorized sub-valve of the
superheater desuperheating water by means of
interlocking
When the second stage desuperheating water control
(6) valve at B side of the superheater is closed(<5%) or
MFT motion or load is less than 20%, close the
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Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 18 of 55

corresponding motorized sub-valve of the superheater


desuperheating water by means of interlocking
When the second stage desuperheating water control
valve at B side of the superheater is opened(>5%),
(7) open the corresponding motorized sub-valve of the
superheater desuperheating water by means of
interlocking
When the third stage desuperheating water control
valve at A side of the superheater is closed(<5%) or
(8) MFT motion or load is less than 20%, close the
corresponding motorized sub-valve of the superheater
desuperheating water by means of interlocking
When the third stage desuperheating water control
valve at A side of superheater is opened(>5%), open
(9) the corresponding motorized sub-valve of the
superheater desuperheating water by means of
interlocking
When the third stage desuperheating water control
valve at B side of superheater is closed(<5%) or MFT
(10) motion or load is less than 20%, close the
corresponding motorized sub-valve of the superheater
desuperheating water by means of interlocking
When the third stage desuperheating water control
valve at B side of the superheater is opened(>5%),
(11) open the corresponding motorized sub-valve of the
superheater desuperheating water by means of
interlocking
When each stage desuperheating water control valve
of the superheater is closed (<5%), close the
(12)
corresponding motorized sub-valve of the superheater
desuperheating water by means of interlocking
When each stage desuperheating water control valve
of the superheater is opened((>5%), open the
(13)
corresponding motorized sub-valve of the superheater
desuperheating water by means of interlocking
When MFT motion or load is less than 20%, the main
motorized valve and motorized sub-valve of reheating
system desuperheating water shall be closed by means
(14)
of interlocking, and each desuperheating water control
valves shall be automatically transformed into manual
operation and closed.
When the desuperheating water control valve at A side
of the reheater is closed(<5%) or MFT motion or
(15) load is less than 20%, close the corresponding
motorized sub-valve of the reheater desuperheating
water by means of interlocking
When the desuperheating water control valve at B
side of the reheater is opened(>5%), open the
(16)
corresponding motorized sub-valve of the reheater
desuperheating water by means of interlocking
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When the desuperheating water control valve at B


side of the reheater is closed(<5%) or MFT motion or
(17) load is less than 20%, close the corresponding
motorized sub-valve of the reheater desuperheating
water by means of interlocking
When the desuperheating water control valve at B
side of the reheater is opened(>5%), open the
(18)
corresponding motorized sub-valve of the reheater
desuperheating water by means of interlocking
When the emergency spraying control valve of the
reheater is closed(<5%) or MFT motion or load is less
(19) than 20%, close the corresponding emergency
spraying motorized sub-valve of the reheater by
means of interlocking
When the emergency spraying control valve of the
reheater is opened(>5%), open the corresponding
(20)
emergency spraying motorized sub-valve of the
reheater by means of interlocking
Main motorized valve of heating steam at the boiler (starting)bottom
Starting is allowed when FBT (furnace bottom
(1)
temperature) is less than 80℃ and MFT exists
Without MFT, close is made by means of interlock
(2)
and starting is forbidden.
When drum pressure reaches 0.2Mpa, close by means
(3)
of interlocking is performed and starting is forbidden.
Motorized valve of steam supply pipe from the cold section of boiler reheater to the auxiliary
steam main pipe
Starting is allowed when the pressure of cold section
(1) of reheater is greater than that of the auxiliary steam
main pipe
Close is made by means of interlock and starting is
forbidden when the pressure of cold section of
(2)
reheater is equal to or less than that of the auxiliary
steam main pipe
Close is made by means of interlock and starting is
(3)
forbidden when the load of unit is greater than 70%.

11.2.5 Interlock protection test on flue-gas temperature probe and pneumatic oscillating device of
burner, including:

Fixed
No. Test item Results Remarks
value

Flue-gas temperature probe A(DCS)

(1) Forward, reverse, suspend, reset(ensuring that the


advancing and regressing travel is in place)
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Commissioning
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(2) Repeat(automatic)

(3) Over-load trip, alarm

(4) High temperature, alarm

(5) High high temperature, quit automatically , alarm

Flue-gas temperature probe B(DCS)

(1) Forward, reverse, suspend, reset(ensuring that the


advancing and regressing travel is in place)

(2) Repeat(automatic)

(3) Over-load trip, alarm

(4) High temperature, alarm

(5) High high temperature, quit automatically , alarm

11.2.6 Interlocking protection test on pneumatic oscillating device of burner, including:

Fixed
No. Test item Results Remarks
value

Pneumatic oscillating lower device group of burner

(1) DCS command is consistent with the one of site


feedback(0%, 50%, 100% command)

(2) Site openness is consistent with the actual position

(3) Horizontal position deviation is less than 5%

(4) Automatically adjusting to the horizontal


position(50%) after MFT

Pneumatic oscillating upper device group of burner

(1) DCS order is consistent with the one of site


feedback(0%, 50%, 100% order)

(2) On-site openness is consistent with actual position

(3) Horizontal position deviation is less than 5%


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(4) Automatically adjusting to the horizontal


position(50%) after MFT

11.2.7 Interlock protection tests on flame scanning fan, including:

Fixed
No. Test item Results Remarks
value

(1) Stop permissive conditions

1) MFT action has delayed for 12h, or another flame


scanning cooling fan is running, air pressure of flame
scanning cooling fan is normal (5kPa-8kPa) and
furnace temperature is less than 80℃

(2) Interlock protection

1) Flame scanning cooling fan is in standby state and the


other flame scanning cooling fan is out of work

2) The flame scanning cooling fan is in standby state and


its low main pipe pressure signal is transmitted

(3) Operation and standby conditions

1) Any flame scanning cooling fan runs

11.2.8 Interlock protection test for intermittent bolwdown pit, including:

Fixed
No. Test item Results Remarks
value
(1) Draining pump A
1) Interlock starting condition:
(1) When the interlock button is pressed, the draining
pump B in the intermittent bolwdown pit has
tripped or has been operated. If the water level is
high, it shall be delayed by 20S.
(2) Button A is selected to press, the water level of
intermittent bolwdown pit is high and two pumps
have not operated uniformly.
2) Conditions for interlock suspension :
‹ Water level of the intermittent bolwdown pit is
low;
‹ Two pumps has operated uniformly, the water
level of intermittent bolwdown pit is
intermediate, the button A is selected and isn’t
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Commissioning
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pressed.
(2) Draining pump B
1) Conditions for interlock initiation including the
followings:

(3) When the interlock button is pressed, the draining


pump B in the intermittent bolwdown pit has
tripped or has been operated. If the water level is
high, it shall be delayed by 20S.
(4) Button A is selected to press, the water level of
intermittent bolwdown pit is high and two pumps
have not operated uniformly.
2) Conditions for interlock suspension :
‹ Water level of the intermittent bolwdown pit is
low;
‹ Two pumps have operated uniformly, the water
level of intermittent bolwdown pit is
intermediate, the button A is selected and is not
pressed.

11.2.9 Interlock protection test on flame CCTV, including:

Fixed
No. Test item Results Remarks
value

(1) Flame CCTV A

1) Conditions for interlock quit :


‹ Alarm on out of gas supply at flame CCTV A
side
‹ Alarm on over temperature at flame CCTV A
side

(2) Flame CCTV B

1) Conditions for interlock quit: (following condition


or):
‹ Alarm on out of gas supply at flame CCTV B
side
‹ Alarm on over temperature at flame CCTV B
side

Inspect and operate the following system according to the sequence (the specific operation
refers to the operation manual on boiler)
11.3 Inspect and operate the cooling water and compressed air system
(1) The circulation water system and the corresponding interlock protection are put into
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operation;
(2) The demineralization replenishment system and the corresponding interlock protection
are put into operation;
(3) The cooling water system of the steam turbine and the corresponding interlock
protection are put into operation;
(4) The cooling water system of the boiler and the corresponding interlock protection are
put into operation;
(5) The compressed air system and the corresponding interlock protection are put into
operation;
11.4 Inspect and operate the high and low-pressure water supply system, feed the water to
the boiler, blow and prepare the hydraulic test for boiler
(1) Inspect and confirm whether the system is provided with starting conditions, start the
condensation system and feed the water to the deaerator;
(2) Inspect and confirm whether the electric water supply pump and its system are ready for
starting. (run the corresponding interlock protection), start a water supply pump;
(3) Confirm that the boiler is ready for feeding and feed the water to the boiler;
(4) Flush the waterside part of the desuperheating water system of superheater;
(5) Inspect and confirm that the boiler proper and its system are provided with the water
pressure condition;
(6) After the boiler water feeding is up to the visible water level, confirm that it is provided
with the water pressure condition.
11.5 Water pressure test for boiler
11.5.1 Scope for water pressure: rear of water supply console --- economizer---drum and
water-cooling wall --- superheater— at the block plate of water pressure for the main steam
pipeline (the water pressure block plate is required to be installed and removed after the water
pressure test is completed.)
11.5.2 Control for water feeding speed
(1) Water feeding flow: 30-60 tons/h;

(2) Water feeding duration: 2-4 hours;


(3) Temperature for water feeding: 40―70ºC;
11.5.3 After water emits from the air vent fully, close the corresponding air valve.
11.5.4 After all the air valves are closed, pressure rising begins.
11.5.5 Pressure rising speed:
(1) Drum pressure<0.98MPa;pressure rising speed <0.244MPa/min;

(2) Drum pressure>9.80MPa;pressure rising speed <0.196 MPa/min ;

(3) Drum pressure>17.00MPa;pressure rising speed <0.098 MPa/min 。


11.5.6 When the pressure rises up to the values below, the pressure rising should be maintained for
inspecting and confirming whether there are leaking points and other abnormality.
(1) Drum pressure:5.88MPa;
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(2) Drum pressure:11.77MPa;

(3) Drum pressure:17.50MPa。


11.5.7 When the drum pressure rises up to 17.40MPa, inspect that the system is free of leakage and
shut off the water supply and watering valves as well as lower the rotary speed of water
supply pump to ensure that the outlet pressure of water supply pump is up to 15.00 MPa,
meanwhile, 5 minute timing begins; if the reduction value for the drum pressure is less than
0.50MPa, water pressure test is qualified. Otherwise, the leakage for the system should be
inspected.
11.5.8 After the water pressure test is completed, pressure reduction begins. The speed for pressure
reduction is equal to or less than 0.50MPa/min.
11.5.9 In the process of depressurization, flush the system below:
(1) Sampling pipeline for superheated steam, saturated steam and boiler water
(2) I&C pipeline for drum pressure and superheated steam pressure
11.5.10 Open the drain valve for the superheater and main steam pipeline as well as the discharge
valve for water cooling wall to drain the water.
11.5.11 Dismantle the water pressure block plate of the main steam pipeline
11.5.12 Flush the cold state water of boiler. The watering and draining work of the boiler should be
carried out for many times until the boiler water is adjacent to the water quality of
demineralization water.
11.6 Ignition preparation
11.6.1 After receiving the ignition command, perform the preparation prior to ignition according to
the operation regulation.
11.6.2 Prior to ignition, the operator should carry out the overall inspection for the equipment and
system, the blow command group should organize the related personnel to perform the
inspection and test for following items:
(1) Inspect that the clearance of expansion of each position is greater than the specified
expansion value, all the expansion indicators should be in zero position and the record
should be made properly.
(2) Inspect whether the nozzles of each burner are in the horizontal location.
(3) Inspect the fastening condition of each hanger; all kinds of hangers and suspenders
should be secure.
(4) Perform the programmed control test for the subsidiary blowing of air pre-heater.
(5) Perform the operation test for each damper, baffle and motorized valve;
(6) Perform interlock, protection and signal tests and inspect the protective setting value;
(7) The operational test for inspection of the furnace flue-gas temperature probe and starting
for the flame-scanning fan.
(8) Operation test for the temporary control door
(9) The appearance inspection for the temporary blowing pipeline; the supports and hangers
should be secure and the density should be satisfied not to produce the vibration or
displacement arising from the counter force of airflow.
(10) Confirm the water level for the drum is at +200MM; systems such as the sealing for the
boiler bottom, deslagging, heating of electric precipitator, draining of boiler and air vent
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are put into service. Start the oil pump, the stokehole circulation is made for the fuel.
(11) Ensure the compressed air system and water cooling system are put into service;
(12) Start up the water feeding of boiler and ignition. Contact the shift supervisor to supply
the steam to the auxiliary steam header.
(13) Operate the heating system of furnace bottom, control the temperature rise ratio ≤28℃
/h and control the upper and lower wall temperature difference of drum≯40℃.
(14) Notify the steam turbine to run the lubrication oil system and the jacking oil system as
well as the barring device;
(15) Prior to ignition, start up the bypass valve of the temporary control valve and the
drainage relevant with the blowing system to avoid water impact accidents.
(16) Operate the sealing system for the boiler bottom and establish the sealing.
(17) Inspect the lubrication oil station of the preheater and start the operation of the oil
station (the oil pump is in the standby state and to be started);
(18) Inspect the cooling fan system of the induced draft fan and run the cooling fan and the
interlock.
(19) Inspect the lubrication oil station of the forced draft fan and run the oil pump and the
interlock.
(20) Inspect the preheater, induced draft fan and forced draft fan and confirm that they are
ready for starting.
(21) Operate the flame scanning cooling air system and the interlock.
(22) Inspect the SCS system to ensure that such interlock protection for the pre-heater,
induced draft fan and the forced draft fan is in operation state.
(23) Inspect the BMS system to ensure that the management system for boiler burning is in
operation state.
(24) Run flame and water level CCTV;
(25) Inspect and confirm the fuel system and put into operation.
(26) Inspect and confirm that the I&Cs are ready for use.
(27) In accordance with the requirement for the start and operation manual of unit, confirm
that each drain valve should be in the correct state prior to ignition.
(28) Open the drainage at different levels for the main steam pipeline at the steam turbine
side, the steam-reheating pipeline at the cold and heat section and high -low bypass
system.
(29) Properly isolate the system related to the blowing system to ensure the steam of
blowpipe is not mixed into other systems.
(30) Open the bypass valve of the motorized valve controlled temporarily for blowing.
(31) After the target device is fitted via the cold state, confirm that it is reliable and available
(32) Confirm that the removal for the water pressure block plate is completed and the system
is restored normally.

12. Temperature rising and pressure rising for boiler ignition


12.1 Confirm that the ignition condition is provided to get the approval of the general director for
commissioning. According to the DCS procedure, employ the light diesel to ignite.
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(1) Start the flame scanning cooling fan and implement interlock of standby fan.
(2) Suspend the heating system at the bottom and ensure the drum level is at about -100mm.
(3) Start two air preheaters and use interlock.
(4) Start the induced draft fan and forced draft fan.
(5) Establish the airflow for blowing, blowing the furnace for 5 minutes and resetting MFT.
(6) Perform the leakage test for fuel system.
(7) After the leakage test is qualified, blow it once more and reset MFT, adjust the total
airflow and the openness of the secondary damper, the pressure difference for the
secondary air of furnace is 250~450Pa, the negative pressure of furnace is about -50Pa.
(8) Inspect the openness for all the baffles on the air duct and flue are in proper location.
(9) Confirm that the boiler protection has been inputted fully. If the conditions are not met,
the protection should be approved by the headquarter, I&C is cut off temporarily and the
record should be made properly. When the protection conditions are met, timely notify
I&C to put into protection.
(10) Establish and maintain the boiler fuel pressure within 3.1-3.3 MPa. According to the
condition, ignite and start 1~ 2 oil guns; after ignition, take notice to inspect the ignition
and atomizing condition and timely adjust the operation condition of oil gun to ensure
the favorable atomizing and clear flame, free of black smoke. At the initial stage of
ignitions, the oil gun at the lowest layer should be selected to start in opposite angle, the
angles should be switched once as per 30 minutes ( such as: the first and the third angle
are tangent towards the second and the fourth corner) to ensure the uniform heating of
water cooling wall. When filling the oil, the condition for air distribution should be
inspected and the proper adjustment should be made timely to ensure the full ignition;
the oil gun with insufficient ignition should be dismantled to inspect and clean; after the
ignition fails or the oil gun put out a fire, timely cut off the fuel; after the blowing for
the oil gun and furnace ventilation is completed, the re-ignition can be made.
(11) Notify the thermal technician to debug the oil fire check. After the oil fire is debugged
normally, the flame check should be started immediately.
(12) After the ignition is normal, the flue-gas temperature probe at the furnace outlet shall be
used. When the steam fails to get through the reheater, the flue-gas temperature at the
furnace outlet controlled shall not exceed 538℃ during pipe blowing. If the flue-gas
temperature exceeds 538℃, fuel quantity should be reduced timely to ensure the safe
operation of the reheater.
(13) Other oil guns should be commissioned continuously, and the combustion adjusting
work and the fire check commissioning work should be carried out. After the oil burner
functions normally, the standby one will be out of service immediately.
(14) The auxiliary steam blowing for the air preheater should be started uninterruptedly.
(15) Based on the temperature rising and pressure rising speed, it is required to increase the
oil gun additionally. The temperature rising and pressure rising speed shall be controlled
in compliance with the temperature/pressure rising ratios for boiler water saturation,
referring to the table below:

Main steam pressure MPa <0.98 0.98--3.92 3.92--9.8 9.8--18.2


Temperature rising ratio℃/h <28 <56 ≤30 ≤36
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Pressure rising ratio MPa/min --- ≤0.03 ≤0.05 ≤0.06

(16) When the boiler starts up for the first time, it is noticed specially to monitor the
expansion conditions in each position. The dedicated person is required to record the
expansion for installing and operation. The expansion time is recorded: prior to boiler
water feeding and after feeding; the drum pressure at the stage of ignition and pressure
rising refers to 0.49 MPa, 1.47 MPa, 2.45 MPa, 3.43 MPa, 4.20 MPa, 5.86 MPa and
6.50 MPa. If the expansion is affected or the expansion is abnormal, the report should be
conducted to suspend the pressure rising, after the abnormity is eliminated by taking the
measures via negotiation, the pressure rising can be performed continuously.
(17) The temperature difference for the upper and lower wall of drum should be controlled
up to be less than 40℃.
(18) When temperature is rising and the pressure is rising, open the related drain valve as
well as monitor and maintain the pipe wall for the super heater and reheater not
overheating.
(19) When the drum pressure rises to 0.2MPa, shut the drums and the air valve for the super
heater at different levels and shut all atmospheric relief valves.
(20) When the drum pressure rises to 0.3-0.5MPa, flush the local water level gauge of drum.
The Contractor flushes the instrument tube, sampling pipe and hot spring bolts.
(21) In the process of temperature and pressure rising as well as pipe blowing, the quality of
boiler water should be controlled. Based on the analysis for the chemical water quality
of the boiler, the sewage discharge shall be performed to improve the boiler water
quality. Therein, the sewage discharge should be performed regularly and the program
control should be used as possible.
(22) When the drum pressure rises to 0.5-1.0MPa, close the drain valve beside the boiler as
well as arrange the chemical dosing system and continuous drainage work regularly,
strengthening the drainage of grain collector.
(23) When the drum pressure rises to 1.0MPa, open the bypass valve of control valve to
warm the pipe. When warming the pipe, the expansion condition for the pipeline and the
stress condition for the supports and hangers should be inspected, especially for
inspecting the strictness of block plate for the high and medium pressure main steam
valve as well as the expansion and stress condition of temporary system. If the problems
are found, timely report it and take the measures to cope with it.
(24) When the drum pressure rises to 3.0MPa, the temperature of super heating steam is
greater than 350℃ and the exhaust temperature of the temporary pipe is greater than
180℃, the trail blowing work for the first time can be carried out.
(25) After steam is generated from boiler and steam pressure is established, strengthen the
monitoring for the cylinder temperature of steam turbine. Monitor the turbine-turning
device to ensure the continuous operation.
13. Blowing procedure
13.1 Trail blowing
Prior to the formal blowing, four trail blowing tests with drum pressure of 3.0MPa, 3.5MPa,
4.0MPa and 4.5MPa shall be performed to inspect the safety and operation of the whole
blowing system. The operators and the operators for the control valve should seek for the
operation skill and master the control method for water level to ensure the accurate display for
the water supply flow.
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When performing the trail blowing every time, sufficiently warm the pipe and strictly inspect
the expansion and stress conditions, after the expansion and stress conditions for the system
(including the temporary system) are confirmed to be normal, the formal blowing can be
performed. During the trail blowing, if the problems are found, timely report and eliminate
them. If the major problems are found, timely report them, shut off the temporary control
valve and break off the power supply as well as stop blowing; after the measures are taken to
demolish the hidden troubles, perform the trail blowing again.
(1) When the drum pressure rises to 3.0MPa, the first –time trail blowing shall be performed.
Open the control valve of blowing and close it after full open.
(2) Inspect whether the heat expansion and the stress of bracket are normal for the blowing
pipeline system, after the normality is confirmed, the pressure rising is made again to
prepare the purge next time. Otherwise, the pressure rising is suspended to treat the
problems on heat expansion and stress of bracket.
(3) When the drum pressure rises to 3.5MPa, the second trail blowing shall be performed.
When performing the second trial blow, add a piece of target on the target device to
show the original state of pipeline system.
(4) Inspect whether the heat expansion and the stress of bracket are normal for the pipeline
system of blowpipe, after the normality is confirmed, the pressure rising is made again
to prepare the purge next time. Otherwise, the pressure rising is suspended to treat the
problems on heat expansion and stress of bracket.
(5) When the drum pressure rises to 4.0MPa, the third trial purge shall be carried out.
(6) Inspect whether the heat expansion and the stress of bracket are normal for the blowing
pipeline system, after the normality is confirmed, the pressure rising is made again to
prepare the purge next time. Otherwise, the pressure rising is suspended to treat the
problems on heat expansion and stress of bracket.
(7) When the drum pressure rises to 4.5 MPa, the fourth trial blow shall be carried out.
Inspect whether the heat expansion and the stress of bracket are normal for the blowing
pipeline system, after the normality is confirmed, the pressure rising is made again to
prepare the purge next time. Otherwise, the pressure rising is suspended to treat the
problems on heat expansion and stress of bracket.
(8) When the drum pressure rises to 5.5 MPa, the formal blow shall be carried out.
13.2 The formal blow at the first stage
Formal blow: the pressure to open the temporary valve is around 5.5~6.5MPa, when the drum
pressure is about 3.8~4.2MPa, shut off the temporary valve. The pressure control after the
valve closing for blowing every time should be based on the principle that the saturated
temperature of drum is not greater than 42℃. When blowing, start up the pressure of
temporary control valve and the pressure of valve closing, the blowing parameters shall be
selected according to table 9.1.
(1) The blowing process for pressure reduction belongs to the working condition that the
parameters vary violently, the water charging operation for the boiler should be paid
attention specially. Prior to opening the control valve, the water level shall be controlled
around -50-- -100mm, under the premise of reliable water supply, open the temporary
control valve. After the temporary control valves are opened fully, the water charging
capacity should be increased gradually; prior to closing the temporary control valve,
water charging capacity should be increased, after the temporary control valves are
closed fully, the water level shall be changed from the false water level to the true water
level, until the water level drops continuously no longer and begins to rise, the water
charging capacity can be reduced to ensure that the water charging reaches the normal
water level. The water charging temperature should be raised as possible; in addition,
the preparation for the water capacity should be sufficient.
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(2) In the process of blowing, the date acquisition should be conducted according to the
record form prepared previously. It is noticeable that the data acquisition should be
complete.
(3) In the process of blowing, a set of pulverizing system of E or D shall be used according
to the combustion condition. After the pulverizing system is put into operation, the metal
temperature of the pipe wall for the super heater or reheater should be monitored strictly
not overheating. After pulverizing, the outlet temperature of superheater or the reheater
should be confirmed whether to be controlled effectively below 450℃. It is prohibited
to operate at over temperature.
(4) The blowing coefficients shall be calculated according to the differential pressure
method to adjust the blowing pressure up to the appropriate value.
(5) After around 20- time blowing is performed, two-time target practice on target shall be
conducted; the blowing -down time more than 12 hours should be arranged according to
the situation.
(6) Prior to shutdown cooling, blow the following systems: Blowing pipes for each stage
desuperheating water of superheater as well as the steam -side pipeline for the
emergency spraying system of reheater. About 5-time blowing with duration of 3~5
minutes every time should be performed for each pipeline.
(7) At least 12 hours are required for shutdown cooling. After flameout, great airflow is
required to blow the furnace for 5 minutes, sealing the furnace.
(8) During cooling, the following operation should be performed:
1) Heat standby of boiler. Maintain the normal water level; monitor and record the
flue-gas temperature at the back-end; prevent the combustion accidents at the
back-end and carry out the accident anticipation.
2) Arrange the workers to clear the grain collector;
3) Clear the strainer of the electric water supply pump;
4) Eliminate the defects found at this stage;
5) Resume the desuperheating water pipeline system at different stages for the
superheater (after the pulverization is used at the first stage of blowing, if the
steam temperature exceeds 450℃, it shall be out of control.)
6) Resume the pipeline of emergency spray water system for the superheater (after
the pulverization is used at the first stage of blowing, if the steam temperature
exceeds 450℃, it shall be out of control.)
7) Installing and commissioning the control valve and flow device for the
desuperheating water system. (note: the necessary measures should be taken to
prevent the foreign matters remaining inside the pipeline during installation.).
13.3 Formal blowing at the second stage
(1) After the system is cooled for 12 hours, the reigniting, pressure rising and pipe warming
for the boiler shall be performed.
(2) The trail blow for the drum pressure at 3.0~5.0MPa shall be carried out to ensure that
the system is heated sufficiently to inspect the expansion and stress conditions.
(3) If there is free of abnormity, continuously raise the pressure up to 5.5~6.5 MPa to
perform the formal blowing.
(4) Based on the requirement of temperature rising and pressure rising, after the condition
of coal feeding is met, the E or D pulverization system should be put into operation. The
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combustion adjustment should be performed and I&C should be performed dynamic


commissioning and operation for coal flame scanning.
(5) During blowing at this stage, alternatively perform the blowing of high and low pressure
bypass pipeline blowing as well as the service steam system blowing for the steam
system. 4~ 5-time blowing is performed respectively. The manual clearing is performed
for the low-pressure bypass pipeline.
(6) Repeatedly perform the formal blowing, until the target is qualified.
(7) Acceptance and appraisal for blowing quality: at the later stage of blowing, inspect the
target installing and blowing condition, continuously inspect the target installing; after
two-time continuous inspection is qualified via the supervisor, when blowing is
completed, and quality acceptance and assessment shall be conducted.
(8) Prior to completion of blowing, strengthen the blowing work at the back end.
(9) After blowing is completed, the great airflow is required to blow the furnace for 5
minutes after the boiler flameout, the furnace should be sealed. The boiler cools
naturally. When the drum pressure reaches 0.8MPa, the boiler draining shall be carried
out. The draining with pressure and residual drying shall be taken to perform the dry
protection.
(10) The steam turbine should keep the turning device operating until the cylinder
temperature of steam turbine reaches the shutdown condition for the turning device to
shutdown the turning device.
(11) When the boiler is not cooled up to the normal temperature, the normal water level
should be remained. When operating, the flue-gas temperature of back-end is required to
be monitored and recorded; preventing the combustion accident at the back-end and the
accident anticipation should be performed properly.
(12) When the drum pressure drops to the normal temperature, the restoration for the
temporary pipeline system can executed via approval.
13.4 During blowing at the second stage, the coal burner and the coal pulverizing system are put
into service
(1) Start ventilation and blow the furnace, resetting MFT.
(2) Start the primary air fan and seal the fan.
(3) Confirm the opening for the drain valve of superheater or the reheater, the draining of
the main steam pipeline at the steam turbine side and the bypass draining of temporary
control valve.
(4) Inspection prior to starting the fuel oil system and oil gun
(5) Operate the flue-gas temperature probe of furnace; start the fire scanning cooling fan,
interlock; confirm that the primary and the secondary valves are closed for the lower
heater of the water cooling wall; inspect that the openness for all the baffles on the air
duct and flue duct should be located in the correct location and confirm that the
deslagging system functions normally .
(6) Confirm that the condition of the coal filling layers is satisfied; ensure that the number
of the oil gun for the furnace is up to over 8 pieces, in addition, the temperature of hot
air should be greater than 150℃, and then the coal pulverizing begins.
(7) Take the operation for the E coal pulverizing system as the sample: open the blanking
valve supplying the coal powder for E –layer burner.
(8) Adjust the primary airflow of the coal mill up to 50t/h and warm up the mill E for 15
min..
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(9) Confirm the oil guns in the AB layer are burned, the combustion should be stable; when
outlet temperature of mill E is up to 65℃--82℃, start up the coal feeder E, and timely
increase the coal quantity of coal feeder E up to the lowest coal supply capacity of
8--10t/h ( the coal feeding ratio is 20%--25% rated output of coal mill), under the low
load ratio, if the coal mill is found vibration, the coal feeding capacity should be
increased, generally, after the coal bed is formed between the mill bowl and mill roller,
the vibration can disappear.
(10) The iginition of the burner should be confirmed to be normal. If the coal powder can not
be burned timely, immediately suspend the coal feeder. After the causes are analyzed, it
can be put into service.
(11) After each burner burns for 10 mins stably, adjust the coal capacity of coal feeder
appropriately based on the curve of temperature rising and pressure rising. The normal
operating parameters for the coal mill should be monitored and maintained to avoid the
vibration and the abnormality of the bearing temperature. After the favorable
combustion is ensured, I&C should be performed hot commissioning for coal flame
scanning. After the fire scanning commissioning is normal, startup should be performed
timely.
(12) After the coal powder is put into service, the steam temperature and the steam pressure
can rise greatly. The oil filling capacity should be reduced appropriately to control the
combustion ratio. When the steam does not get through the reheater, during blowing, the
flue-gas temperature at the outlet should be controlled not to exceed 538℃, if the
flue-gas temperature exceeds 538℃, fuel feeding should be lowered to ensure the safety
operation of reheater. During blowing, the steam pressure and the temperature for the
super heatershould be controlled to below 7.0 MPa and 450℃ respectively. Otherwise,
the combustion is required to be weakened
13.5 Complete trial run record
The main parameters in the commissioning of boiler blowing should be listed in the Record
List for Parameters of Boiler Blowing, referring to Appendix 3.

14. Safety Measures


14.1 Safety rules for commissioning
14.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant
safety rules on site, and wear reasonable clothing and appropriate personal protective
equipments.
14.1.2 In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Investigate the cause and take corrective measures.
14.1.3 The parties participating in the commissioning will obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
14.1.4 In the entire process of blowing, all the professionals should be in post to ensure the safety for
the equipment operating.
14.2 Personal Risk and Preventative Measures
‹ Rotating the equipment
Injuries might be caused by rotating equipment during commissioning or test. Therefore,
special care must be taken during work and do not touch the rotating components with
tools or your hand。
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‹ Failing to wear or misuse the safety helmet


When adjusting or testing, injuries and deaths might be caused by the striking of the
objects. When entering the production site, properly wear the safety helmet and tightly
tie the cap belt. The dangers above the operation region and the falling objects aloft in
the periphery should be inspected.
‹ The damage and burn arising from blowing temporary pipeline
All the temporary pipelines are required to perform the heat insulation. Prior to blowing,
the pipeline should be warmed sufficiently to avoid the water attack accident, and at
40%—50% and 70%—80% of blowing pressure , trail blowing shall be performed in
several times.
Steam scalding and noise pollution at the exhaust of blowing
The safety isolation measures should be taken strictly at the exhaust of blowing, the
dedicated person should be designated.
‹ The mis-operation for the temporary control valve shall lead to the damage of
equipment and the personnel injury.
Hang the operation prohibiting plate; strictly execute the power failure rule when
replacing the target. For each blowing, the installation contractor must execute it after
the personnel withdrawal.
Strictly follow operation procedures, adhere to operation approval system and never
carry out work not approved。
‹ The high- temperature flue gas emitted from the observation hole and manhole door can
hurt the person.
All the manhole doors and observation holes are sealed and closed respectively. Prior to
observing the fire on site, appropriately raise the pressure of furnace. When observing
the fire, stand on the side of observation hole and prepare to evacuate at any time.
14.3 Equipment Risk and Preventative Measures
‹ Abnormal running of equipment
If it is found that operating equipment makes abnormal sound or has other abnormal
condition, and such problem may not be eliminated, stop such equipment and report to
the control rooms immediately.
‹ Accidental fire and fire hazard of fuel oil system
When commissioning, prepare the strict firefighting measures; the inflammable and
explosive objects should be far way from the periphery of blowing pipeline; the
sufficient firefighting appliances must be provided on site
‹ Ignition of the platform for the coal mill
The dedicated person should be assigned to monitor it. The temporary firefighting
devices are placed herein, and the firefighting system of the coal pulverizing system
should be in standby state.
‹ Ignition and combustion due to over temperature inside the coal mill
The operator should elaborately perform the operation and maintenance and strictly
control the outlet temperature of mill; the routing inspection should be strengthened, the
report should be submitted when finding the problems; several temporary firefighting
devices should be placed, in addition, the firefighting steam system of coal pulverizing
system should be in standby state.
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‹ Iginition of the platform for the burner


The dedicated person shall be assigned and the temporary firefighting devices shall be
placed herein, the telephone or the walkie talkie should be employed to contact with the
central control room.
‹ Deflagration at the time of extinguishing due to unstable combustion
The extinguishing protection must be used, the coal powder fineness should be
controlled reasonably, and the operation and maintenance should be performed
elaborately, if the combustion is instable, timely start the oil gun, properly prepare the
accident anticipation.
‹ Over temperature and over pressure can damage the equipments and hurt the person.
The fuel should be used slowly and stably, the supervising for the wall temperature and
the temperature at the place of flue-gas temperature probe should be strengthened. If the
combustion ratio is out of control, timely shut down the boiler and prepare the pressure
releasing accident anticipation. The outlet pressure of the superheater should be
controlled to be not greater than 7.0 MPa, the temperature for the superheater or the
reheater should not be greater than 450℃.otherwise, the combustion must be weakened
and the pressure releasing must be performed.
‹ The combustion of pulverized coal deposits at the back-end damaging the equipment
The regular analysis should be performed and the coal fineness should be remained
within the specified scope. The combustion adjustment should be strengthened to ensure
the favorable combustion. The air pre-heater should be started continuously to perform
the soot blowing. After shutdown, the normal water level must be remained; the closed
system must be purged with the great air flow, meanwhile, the monitoring for the
flue-gas temperature at the back-end should be strengthened, if the problem is found,
timely treat it; irregularly inspect the accumulated dust at the convection flue gas pass;
prior to starting the boiler once more, the great air flow should be employed to purge the
boiler. The dedicated person should be assigned to monitor, the temporary firefighting
device and firefighting system placed herein should be in standby state.
‹ Serious water scarcity or overfeeding accident
The proper control of drum water level is essential for blowing. Water supply of drum
should be controlled properly; the water supply should be stable to avoid the overload
for the pump, meanwhile, the false water level and true water level for the blowing
should be distinguished to ensure not producing the serious water scarcity or
overfeeding accidents.
Requirement for water level control: after the control valve is opened, the steam
pressure drops rapidly, meanwhile, the drum level also rises sharply, even overfeed,
which is the false water level, now, the water supply should not be reduced, and on the
contrary, with opening of blowing valve, the water supply capacity should be increased
gradually. When the temporary control valve on blowing is closed, the drum level also
drops, even the water level is invisible, therefore, when beginning to close the control
valve, the water supply capacity should be increased, the water level for full closing of
control valve should be remained in the visible water level as possible. When the water
level begins to rise again, the water supply should be reduced immediately to avoid the
over high water level. In order to avoid the serious water carrying of steam, prior to
blowing the open valve, the drum level should be controlled around -100mm.
‹ Preventing the water attack accident
When blowing the pipe, the pipe warming should be warmed up sufficiently to avoid the
water attack accident. Prior to blowing, the drain valve on the main steam pipeline
should be opened completely; in addition, the warm pipeline behind the drain valve
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should be confirmed locally, the temperature is up to over 180℃; when performing the
formal blowpipe, the drain valve on the main steam pipeline should be closed up to 1/3
of the full openness. During blowing the pipe, the openness condition for the bypass
valve of the temporary control valve should be known specially. When the interval of
blowing is too long (more than 2 hours), the bypassvalve should be opened fully, if
necessary, a part of the temporary control valve should also be opened to ensure that the
pipe warming is sufficient prior to blowing for the whole pipeline system.
Water inflow and steam admission of gas cylinder
During blowing the pipe, in order to prevent that the water and steam from entering into
the gas cylinder, the temporary blowing system should be connected according to this
measure strictly, and the isolation measures should be taken properly, meanwhile, the
monitoring on cylinder temperature should be strengthened, the turning device system
should be put into service.
14.4 Points for Attention of Safety
‹ The uniform commissioning organization and the command should be established for
blowing work of boiler. The sufficient personnel on operation, maintenance and
safeguard should be provided. The production operators should be trained. The agents
and the production operators should be familiar with the relevant equipment system,
aware of the commissioning measures and understand their work scope and
responsibilities as well as be familiar with the operation methods to prevent
misoperation.
‹ All the staffs to participate in blowing should observe the relevant safety stipulation on
site. The flaw detection for all the steam and water system as well as the main reheating
steam pipeline should be qualified to ensure that the blow work is carried out safely and
reliably.
‹ For the first ignition, the installation and manufacturing contractors should assign the
dedicated person to inspect the expansion condition on boiler and steam pipeline system
and record it properly. The fixing plugs fastened onto the pipeline supports and hangers
should be confirmed to be removed already to ensure the normal expansion of the boiler
and the entire blowing system.
‹ When endangering the safety for the personnel and equipment in the process of blowing
of boiler, the blowing work should be suspended immediately, if necessary, the
operation of unit should be suspended, analyzing the causes and put forwarding the
solution measures. After the accidents are removed, the blowing work shall be
performed according to the decision of the headquarters.
‹ During operating, the touring and inspection regulation on equipment system should be
executed, during touring, if the problems are found; the report should be submitted to
the commissioning and command department.
‹ In the process of blowing, the warning line should be provided within the scope of
commissioning equipment. The inflammable and explosive objects should not be
provided in the periphery of pipeline for blowing. Persons are strictly forbidden in the
periphery of 20m for the exhaust, the safety marks and warning line should be provided
in the periphery, the dedicated person on safety should be assigned to safeguard.
‹ The utility system should be isolated with the unit in construction and the operation
prohibiting marks should be established. After the accident anticipation and the
corresponding measures are taken properly, the blowing work can be developed. The
blowing cannot affect the normal work of the unit installing.
‹ Whether the muffler is installed at the exhaust should be decided and prepared by the
Contractor; if the muffler is required to be installed, the muffler should be fastened on
the cement pier on the zero -meter ground, the manufacturer of the muffler must have
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the certification on fabrication of pressure-bearing parts to guarantee the safety of


blowing. The steam discharge capacity for the muffler should be 720 tons/h. the main
parameters of muffler covers: Di≥670mm in inet dimension (being equal to or more than
cross section of discharge pipeline), 300~400℃ in work temperature and being equal
to or less than 1KPa for the pressure reduction that the steam gets through the muffler as
well as being less than 80 DB out of 5m for the noise reduction capacity.
‹ If the muffler is not installed at the exhaust, the huge noises produced by blowing can
affect the living of the residents in the periphery. Considering the environmental
protection, the headquarters should implement the conciliation work properly and decide
the period of blowing. The time arrangemement should conform to the environmental
protection requirement.
‹ During blowing the pipe for the boiler, the firefighting system is in standby state and it
can be used at any time.
‹ When the ignition and pressure rising are carried out for the boiler, the dedicated person
should be assigned to monitor the cylinder temperature of steam turbine, the dedicated
person should be assigned to inspect whether the temporary facilities of high and
medium combined steam valve are found leakage. In case of abnormal conditions,
suspend blowing immediately. During blowing, the dedicated person should be assigned
to inspect whether cylinder temperature rises for avoiding main shaft bending accidents
arising from plenty of steam seeping into the steam turbine.
‹ The proper control of drum water level is essential for blowing. Water supply of drum
should be controlled properly; the water supply should be stable to avoid the overload
for the pump, meanwhile, the false water level and true water level for the blowing
should be distinguished to ensure not producing the serious water scarcity or
overfeeding accidents
‹ When replacing the target or clearing the grain collector, the contact should be
strengthened, the steam -free state and outage of temporary control valve state should be
confirmed to replace the targets and clear the grain collector, after replacing, the
principal on blowing should be notified, and it is strictly forbidden that the control valve
is opened in error to produce the accident.
‹ Prior to opening the control valve for blowing, withdrawal of the person to replace the
targets should be confirmed, there are free of constructors on the pipeline for blowing
and the permission is obtained from the construction principal.
‹ Due to the large pressure difference of temporary rush valve and frequent operation, the
dedicated person should be assigned to maintain and ensure the fluent operation of
blowing.
‹ When blowing the pipe, the pipe warming should be performed sufficiently to avoid the
water attack accident.
‹ In the process of pipe blowing and pressure rising, the speed should be controlled to
avoid the over temperature and over pressure, the temperature difference between the
upper and lower wall of drum should be controlled strictly to be not greater than 40℃.
‹ When the pressure rising and energy storage for the boiler are performed prior to
opening the temporary control valve, the preheater is in parch state basically, the
flue-gas temperature at the outlet of furnace should be strictly controlled to be below
538℃.
‹ Prior to starting, the heating surface of air preheater should be confirmed to be clean,
free of sundries. The soot blowing work of air preheater is performed continuously in
the process of starting and blowing.
‹ In the process of blowing, the condition on oil gun and coal powder combustion should
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 36 of 55

be supervised to avoid oil leakage and entering into the furnace; the unchangeable
combustion should be remained to keep the stable and favorable combustion, the flame
inside the boiler should be distinct, the fluctuation on negative pressure of furnace is
slight; and the furnace is bright and free of black smoke, meanwhile, the variation for
steam temperature, steam pressure, wall temperature and flue-gas temperature should be
supervised strictly to avoid producing the over temperature accident and the ignition
accident of air preheater as well as the reburning accident at back-end.
‹ In the initial stage of coal feeding, the inspection and maintenance for ash and cinder
handling system should be strengthened.
‹ After the operation of coal pulverizing system is stable, the regular analysis should be
implemented and fineness of coal powder should be remained within the scope
specified.
‹ In the entire process of blowing, the Contractor should strengthen the supervising on
expansion and stress condition of temporary system, especially for the trail blowing
stage.
‹ Due to large water consumption in the process of blowing, the supervision on water
level of deaerator and drum should be strengthened, and the continuous chemical water
preparation should be kept to guarantee the fluent operation of blowing work.
‹ When the heat standby or emergency shutdown of boiler is performed after the boiler is
out of service, the normal drum level should be remained. As long as the boiler isn’t
cooled below the normal temperature, the operators should supervise the variation of
flue-gas temperature at the back-end, when there is the abnormal change, the preventive
measures should be taken to organize and implement it pertaining to the specific
problems and the data record should be made properly for future reference.
‹ After blowing is completed and before the pipeline is restored, the construction
conditions must be ensured to be satisfied: after the work sheets on construction
permission are handled properly, the construction can be restored. After blowing is
completed and when the system is stored, the Contractor must take the reliable measures,
strictly prohibiting producing the secondary pollution.
‹ During boiler steam blowing, the record on blowing parameters should be made
properly. After blowing is qualified, the certification procedure should be handled.

15. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 37 of 55

Appendix 1 Blowng condition checklist

Verified Rema
No. Items Requirements Result
by rks
1 Maintenance conditions
Completion of temporary pipe and heat
insulation (including drain, heat insulation, □Yes □No
etc.)
Completion for installation and
commissioning of temporary motorized □Yes □No
valve, bypass valve and drain valve.
Completion for manufacturing and
installation of target device and the quantity □Yes □No
is sufficient.
Temporary piping
Qualified for on/off test and light signal of
(1) system for □Yes □No
temporary motorized valve.
blowing
Completion for installation and acceptance
of temporary piping, fixing and sliding □Yes □No
hanger for counter-force framework
Completion of manufacturing and correct
□Yes □No
installation for the grain collector
Completion for installation and calibration
of the pressure gauge and the thermometer
□Yes □No
installed additionally for temporary system
for blowing.
Air pressure test is completed with
□Yes □No
acceptable quality
Completion for installation and heat
insulation of boiler proper and flue-gas and □Yes □No
Flue-gas and air air duct
(2)
system Single commissioning for each fan and
□Yes □No
commissioning of subsystem
Completion for inspection and adjustment
of various air dampers and baffle with □Yes □No
acceptable quality
Completion for single commissioning and
interlock protection test on flame scanning □Yes □No
cooling fan with acceptable quality
Flame scanning
(3) Completion for commissioning of CCTV
system □Yes □No
system ,putting into service at any time
Qualified commissioning for the flue-gas
□Yes □No
temperature probe of boiler
Electrostatic Completion for installation of electrostatic
(4) precipitator precipitator and heat insulation with □Yes □No
system acceptable quality
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 38 of 55

Verified Rema
No. Items Requirements Result
by rks
Qualified for air-flow distribution test,
pressure rising and rapping test on □Yes □No
electrostatic precipitator
Completion for ash bucket heating device of
the electrostatic precipitator and inspection □Yes □No
with acceptable quality
Completion for single trial use and
installation of oil storage and stokehold fuel □Yes □No
oil system as well as heat insulation work
Completion for hydrotest of the stokehold
fuel oil system and qualification for water □Yes □No
and steam flushing
Completion for installation of steam
blowpipe of fuel oil system and adjustment □Yes □No
on blowing valve
(5) Fuel oil system Completion for motorized valve and
pneumatic valve adjustment of fuel oil □Yes □No
system with acceptable quality
Qualification for the simulation test in
related interlock protection(MFT AND
OFT) of the fuel oil system
Completion of the advancing and regressing
□Yes □No
test for oil gun and high-energy igniter
Completion for each flame check static
□Yes □No
commissioning
Installation of boiler proper and heat
(6) Boiler proper insulation are completed with acceptable □Yes □No
quality
Hydrotest of the boiler is completed with
□Yes □No
qualified acceptance.
Water drainage, bleeding, regular draining,
continuous draining, bottom heating,
installation of nitrogenization system and
□Yes □No
heat insulation are completed fully. All
motorized valve commissioning has been
completed with acceptable quality
The installation for the hydraulic block plate
of the main steam pipeline at the
□Yes □No
superheater outlet has been completed and
shall be removed after hydrotest.
After hydrotest , all the hydraulic valve
cores of the each safety valve for drum and
superheater are removed, restoring formally
□Yes □No
and complying with the requirement of
manufacturer. The hydraulic block plate
shall be dismantled.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 39 of 55

Verified Rema
No. Items Requirements Result
by rks
The spring supports and hangers for
steam-water pipeline are complete and the □Yes □No
pin is removed, with free stress
Motorized and pneumatic valve for each
steam-water pipeline are adjusted to be □Yes □No
qualified
The expansion system of boiler proper is
inspected jointly by each party to be normal
□Yes □No
and the expansion indicator is complete and
adjusted to zero.
Staircase, platform and rail of the boiler are
complete with sufficient lighting and free of □Yes □No
sundries.
After pickling of boiler is completed, the
inner arrangement for the steam drum
should be cleaned to normal, the drum is
□Yes □No
closed and the temporary facilities should
be removed, the formal system has been
restored.
The steam drum water-level gauge has been
installed properly, and the SRTV has been □Yes □No
adjusted and can be put into application
Boiler water sampling and dosing system
have been installed with acceptable
□Yes □No
quality ,providing with the operation
condition
Such systems such as feed water,
desuperheating water, and emergency water
spray have been installed completely. With
qualified blowing, commissioning on
motorized and pneumatic valve have been
□Yes □No
completed. The installation and heat
insulation of temporary back-flush pipes at
steam side of superheater (reheater)
desuperheater are completed with
acceptable quality.
All the manhole doors and inspection holes
□Yes □No
in the boiler proper are complete and closed.
The inspection for burner installation and
coal flame checking commissioning under
□Yes □No
cold state are qualified, with normal
operation conditions.
Installation for slag pit (including the
Ash and cinder furnace bottom sealing), slag tank and
(7) □Yes □No
handling system rotating equipment are completed with
acceptable quality.

After trial use of each single equipment, □Yes □No


on/off test on hydraulic shutoff valve is
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 40 of 55

Verified Rema
No. Items Requirements Result
by rks
qualified and can be put into operation.
The installation and commissioning work
for the dedusting system equipment are
completed, the logical commissioning for □Yes □No
dedusting program control are completed,
providing with operation conditions.
Installation and trial use of each single
equipment are completed with acceptable □Yes □No
quality.
Coal handling
(8) The interlock protection test is qualified. □Yes □No
system
Defects found in system commissioning
have been eliminated, providing with coal □Yes □No
feeding conditions.
Completion of pipe installation and heat
□Yes □No
insulation
Completion of installation and
Soot blower commissioning of motorized and pneumatic □Yes □No
(9)
system valve
It can be put into operation at any time after
completion of soot blowing test of air □Yes □No
preheater.
Completion of installation and heat
□Yes □No
insulation
Qualified for commissioning of sealing fan □Yes □No
Primary air leveling is qualified □Yes □No
Calibration of the air volumn at the inlet of
□Yes □No
coal mill is qualified
Completion of coal mill lubricating oil
□Yes □No
system commissioning
Coal pulverizing
(10)
system Completion of cold state commissioning for
□Yes □No
the coal mill
Completion of trial use of coal mill and coal
feeder, providing with the commissioning □Yes □No
condition;
Completion of the transmission test for
□Yes □No
baffle system and damper
Calibration for coal feeder weighing device
□Yes □No
is qualified.
Completion of installation and heat
□Yes □No
insulation
(11) Air heater system
Completion of trial use of single equipment. □Yes □No
The interlock protection test is qualified. □Yes □No
(12) Compressed air
Completion of trial use for the single and □Yes □No
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 41 of 55

Verified Rema
No. Items Requirements Result
by rks
subsystem of instrument and service air
compressor;
Completion of installation for instrument
and service air gasholder as well as □Yes □No
system checkout of safety valve;
Qualified for instrument and service air
□Yes □No
lines blowing
The interlock protection test is qualified. □Yes □No
Completion of installation □Yes □No
All fire-fighting equipments are complete,
and watering test for firefighting water is □Yes □No
Fire protection
(13) qualified, being in reservation state.
water system
Fire-fighting equipments are complete in
control room, electronic room and fuel oil □Yes □No
system
Completed installation and qualified
□Yes □No
Industrial water hydraulic pressure
(14)
system It can be put into operation after completion
□Yes □No
of trial use.
It can be put into operation after the
completion for installation commissioning □Yes □No
of boiler
Auxiliary steam Completion of installation and heat
(15) □Yes □No
system insulation for auxiliary steam system
The motorized valve of auxiliary steam
system is qualified and can be put into □Yes □No
operation.
Completion of isolation of public with 2#
(16) Isolation □Yes □No
unit
It is provided with the feature of continuous
□Yes □No
Chemistry water chemical water supply
(17)
system Completion of commissioning for water
□Yes □No
charging system
Condenser and hot well is qualified after
cleaning; it is qualified for the condensing
(18) Steam Turbine pump via commissioning, the blowing of □Yes □No
system is qualified and can supply the water
for deaerator.
Inner of deaerator has been cleaned. After
blowing, steam-heated pipelines are
□Yes □No
returned to normal and can be heated and
applied.

The electrically driven feed pump is □Yes □No


qualified after commissioning. After
blowing, the water supply pipeline is
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 42 of 55

Verified Rema
No. Items Requirements Result
by rks
returned to normal and can be put into
operation.
Measures to prevent air from entering the
turbine has been implemented and is □Yes □No
qualified after inspection.
Commissioning for steam turbine vacuum
system is completed and can be put into □Yes □No
operation;
Commissioning for lubrication oil system of
steam turbine, sealing oil system, and
jacking oil system are completed. Turning □Yes □No
device system is normal and can be put into
operation.
The main steam pipeline of steam turbine,
reheating and recooling pipeline of cold and
hot section as well as the high and low
□Yes □No
pressure bypass draining valve are
confirmed to be qualified and can be put
into operation.
The commissioning for temperature
measuring point of steam turbine cyliner
□Yes □No
has been checked and can show accurate
temperature of the cylinder..
All steam bleeding electric intercept valves
are tested and qualified, with strict □Yes □No
closeness.
Drain introduced into the condenser has
□Yes □No
been reliably isolated.
Low voltage turbine water spray can be put
□Yes □No
into operation.
2 Electrical and Thermal Regulating conditions
Completion of interlock test on flame
□Yes □No
scanning cooling fanl
Completion of inspection on furnace
□Yes □No
blowing condition
Completion of MFT test and interlocking
□Yes □No
Boiler test after MFT
FSSS(including
(1) OFT test and completion of interlocking test
fuel oil and coal □Yes □No
after OFT
filling part )
Completion of fuel oil leakage test □Yes □No
Completion of oil gun fueling management
□Yes □No
test
Completion of coal feeder and coal mill
□Yes □No
control as well as interlocking test
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 43 of 55

Verified Rema
No. Items Requirements Result
by rks
Air preheater(A/B) launching and tripping
conditions, programmed start, programmed □Yes □No
stop
IDF(A/B) launching and tripping
conditions, programmed start, programmed □Yes □No
stop
Forced draft fan (A/B) launching and
tripping conditions, programmed start, □Yes □No
Sequential control programmed stop
of auxiliary
(2) engine and Primary air fan (A/B) launching and
interlock and tripping conditions, programmed start, □Yes □No
protection tests programmed stop
Sealing fan (A/B) launching and tripping
□Yes □No
conditions
Coal mill(A/B/C/D/E) launching and
tripping conditions, programmed start, □Yes □No
programmed stop
Feeder (A/B/C/D/E) launching and tripping
□Yes □No
conditions
I&C measuring
The calibration is complted, the indication
(3) points and meter □Yes □No
is accurate
of DAS system
Protection, alarm
as well as It can give alarm after completion of
(4) □Yes □No
acoustic and light transmission commissioning
signals
Emergency power
(5) Applicable □Yes □No
supply
DCS two -way
(6) Applicable □Yes □No
power
Blowing system
(7) Completed for drawing □Yes □No
control drawing
3 Environmental conditions
Traffic Unclogging □Yes □No
(1)
Light Sufficient □Yes □No
Communication
(2) Convenient and unobstructed □Yes □No
equipments
(3) Fire apparatus Sufficient and in stand-by condition □Yes □No
It should be debugged to meet the
(4) A/C system □Yes □No
requirement of the computer equipment
Only after debugged and tested, it can be
(5) Boiler staircase □Yes □No
put into application.
4 Other requirements
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 44 of 55

Verified Rema
No. Items Requirements Result
by rks
Organizing the united major inspection on
construction, Owner, production and
(1) Inspection □Yes □No
commissioning; the problems found should
be dealt completely.
Completion of reparation for production
□Yes □No
commissioning
Qualified training test of the operators □Yes □No
Production
(2) The operation scheme and system drawing
preparation □Yes □No
have been reviewed and approved.
Operation instrument and running log are
□Yes □No
complete.
Chemicals and material preparation for trial
□Yes □No
Resources use are in order
(3)
preparation Chemical water, fuel oil and coal design are
□Yes □No
prepared sufficiently.
Overhaul tools
(4) Prepared □Yes □No
and materials
Commissioning
control and
(5) Sound and clear division of work □Yes □No
organization
system
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Boiler Steam Blowing REV A
Commissioning
Procedure SCCTI-TS-GL-CS-016-2009A Page 45 of 55

Appendix 2 Record list for blowing acceptance

No. Technical Requirements Implementation Remarks


Inner diameter of temporary pipe is equal to or greater than
1 C that of the upstream blowing pipeline

Blowing pressure is 5.5~6.5Mpa, and superheating


2
temperature is 350℃~450℃
Time to open or close the blowing control motorized valve is
3 less than 60S
Blowing scope
(1)Superheater, main steam pipelines, reheater pipelines of
cold section , reheater pipeline of hot section, reheater
4 (2) HP/LP bypass pipeline pf steam turbine
(3) Desuperheating water pipeline of superheater
(4) Such other pipelines as shaft seal gas sources of steam
turbine
During the process of blowing, time for shutdown cooling
5 should not be less than 12h
6 Blowing coefficient of flow method is greater than 1
7 Record for total frequency of blowing
Material and dimension of target
The length is equal to the inner diameter of the pipe where the
8 target is installed
The width is 8% of the length
Material of target is aluminum
Qualified target
9 Quantities of spot in size of 0.2~0.5mm in size C
Quantities of spot is bigger than 0.5mm in size.

Commissioning Contractor Date: Operation Contractor: Date:

Contractor: Date: Dongfang Electric: Date:


Appendix 3 Record Table for Blowing Parameters

Parameters when opening the control


Parameters when closing the control valve Parameters in the process of blowing
valve
Maximal Maximal
No. Time Outlet Exhaust
Drum Temperature Drum Outlet pressure Inlet pressure pressure pressure
pressure of steam Remark
pressure for main pressure of super heater of reheater difference of difference of
super heater pressure s
MPa steam ℃ MPa MPa MPa super heater re- heater
MPa MPa
MPa MPa
Appendix 4 Blowing Diagram
Appendix 5 Blowing Diagram for Desuperheating water Pipeline of SuperHeater or Reheater
Appendix 6 Processing Diagram of Grain Collector
Appendix 7 Checklist for Motorized Valve of Steam-Water System
Motorized Valve Commissioning Record
Local Remote Time
Remot Signatu Remark
KKS code Name position Direc Feed Direc Feed e Date re s
indication tion back tion back
X0LAB40AA001 BOILER FEED WATER MOTORIZED VALVE
BOILER FEED WATER MOTORIZED ORIFICE
X0LAB40AA002
VALVE
BOILER FEED WATER BYPASS CONTROL VALVE
X0LAB41AA001
FRONT MOTORIZED VALVE
BOILER FEED WATER BYPASS CONTROL VALVE
X0LAB41AA002
BACK MOTORIZED VALVE
BOILER FEED WATER VALVE FRONT DRAINING
X0LAB40AA401
MOTORIZED VALVE
BOILER FEED WATER VALVE BACK DRAINING
X0LAB40AA402
MOTORIZED VALVE
ECONOMIZER RECIRCULATING MOTORIZED
X0LAB44AA001
VALVE A
ECONOMIZER RECIRCULATING MOTORIZED
X0LAB44AA002
VALVE B
ROOF SUPERHEATER INLET HEADER DRAINING
X0LCQ52AA001
MOTORIZED VALVE
OPEN SUPERHEATER START-UP EXHAUST
X0LBA10AA501
MOTORIZED VALVE 1
SUPERHEATER START-UP EXHAUST MOTORIZED
X0LBA10AA502
VALVE 2
REHEATER START-UP EXHAUST MOTORIZED
X0LBB10AA501
VALVE 1
REHEATER START-UP EXHAUST MOTORIZED
X0LBB10AA502
VALVE 2
REHEATED STEAM DESUPERHEATING WATER
X0LAF60AA001
MAIN PIPE MOTORIZED VALVE
REHEATED STEAM EMERGENCY
X0LAF61AA001
DESUPERHEATING WATER MOTORIZED VALVE
A SIDE REHEATED STEAM DESUPERHEATING
X0LAF62AA001
WATER MOTORIZED VALVE
B SIDE REHEATED STEAM DESUPERHEATING
X0LAF63AA001
WATER MOTORIZED VALVE
DRUM EMERGENCY DRAINING MOTORIZED
X0LCQ21AA001
VALVE 1
DRUM EMERGENCY DRAINING MOTORIZED
X0LCQ21AA002
VALVE 2
ROOF SUPERHEATER INLET HEADER DRAINING
X0LCQ52AA001
MOTORIZED VALVE
REAR ENCLOSURE RINGED HEADER DRAINING
X0LCQ53AA001
MOTORIZED VALVE 1
REAR ENCLOSURE RINGED HEADER DRAINING
X0LCQ53AA002
MOTORIZED VALVE 2
REAR ENCLOSURE RINGED HEADER DRAINING
X0LCQ53AA003
MOTORIZED VALVE3
REAR ENCLOSURE RINGED HEADER DRAINING
X0LCQ53AA004
MOTORIZED VALVE 4
WALL TYPE REHEATER INLET HEADER
X0LCQ54AA001
DRAINING WATER MOTORIZED VALVE 1
ECONOMIZER INLET HEADER DRAINAGE
X0LCQ55AA001
WATER MOTORIZED VALVE
WALL TYPE REHEATER INLET HEADER
X0LCQ56AA001
DRAINING WATER MOTORIZED VALVE 2
FEED WATER OPERATION PLATFORM DRAINAGE
X0LCQ57AA001
WATER MOTORIZED VALVE
BOILER FEED WATER VALVE FRONT DRAINING
X0LAB40AA401
MOTORIZED VALVE
BOILER FEED WATER VALVE BACK DRAINING
X0LAB40AA402
MOTORIZED VALVE
ROOF SUPERHEATER INLET HEADER DRAINING
X0LCQ52AA001
MOTORIZED VALVE
BOILER FRONT WATER WALL INTERMITTENT
X0LCQ31AA001
BLOWDOWN MOTORIZED VALVE 1
BOILER FRONT WATER WALL INTERMITTENT
X0LCQ31AA002
BLOWDOWN MOTORIZED VALVE 2
BOILER FRONT WATER WALL INTERMITTENT
X0LCQ31AA003
BLOWDOWN MOTORIZED VALVE 3
X0LCQ31AA004 BOILER FRONT WATER WALL INTERMITTENT
XB BLOWDOWN MOTORIZED VALVE 4
BOILER FRONT WATER WALL INTERMITTENT
X0LCQ31AA005
BLOWDOWN MOTORIZED VALVE 5
BOILER FRONT WATER WALL INTERMITTENT
X0LCQ31AA006
BLOWDOWN MOTORIZED VALVE 6
BOILER B SIDE WATER WALL INTERMITTENT
X0LCQ32AA001
BLOWDOWN MOTORIZED VALVE 1
BOILER B SIDE WATER WALL INTERMITTENT
X0LCQ32AA002
BLOWDOWN MOTORIZED VALVE 2
BOILER B SIDE WATER WALL INTERMITTENT
X0LCQ32AA003
BLOWDOWN MOTORIZED VALVE 3
X0LCQ32AA004 BOILER B SIDE WATER WALL INTERMITTENT
XB BLOWDOWN MOTORIZED VALVE 4
BOILER B SIDE WATER WALL INTERMITTENT
X0LCQ32AA005
BLOWDOWN MOTORIZED VALVE 5
BOILER B SIDE WATER WALL INTERMITTENT
X0LCQ32AA006
BLOWDOWN MOTORIZED VALVE 6
BOILER REAR WATER WALL INTERMITTENT
X0LCQ33AA001
BLOWDOWN MOTORIZED VALVE 1
BOILER REAR WATER WALL INTERMITTENT
X0LCQ33AA002
BLOWDOWN MOTORIZED VALVE 2
BOILER REAR WATER WALL INTERMITTENT
X0LCQ33AA003
BLOWDOWN MOTORIZED VALVE 3
OPEN BOILER REAR WATER WALL
X0LCQ33AA004 INTERMITTENT BLOWDOWN MOTORIZED
VALVE 4
BOILER REAR WATER WALL INTERMITTENT
X0LCQ33AA005
BLOWDOWN MOTORIZED VALVE 5
BOILER REAR WATER WALL INTERMITTENT
X0LCQ33AA006
BLOWDOWN MOTORIZED VALVE 6
BOILER A SIDE WATER WALL INTERMITTENT
X0LCQ34AA001
BLOWDOWN MOTORIZED VALVE 1
BOILER A SIDE WATER WALL INTERMITTENT
X0LCQ34AA002
BLOWDOWN MOTORIZED VALVE 2
BOILER A SIDE WATER WALL INTERMITTENT
X0LCQ34AA003
BLOWDOWN MOTORIZED VALVE 3
BOILER A SIDE WATER WALL INTERMITTENT
X0LCQ34AA004
BLOWDOWN MOTORIZED VALVE 4
BOILER A SIDE WATER WALL INTERMITTENT
X0LCQ34AA005
BLOWDOWN MOTORIZED VALVE 5
BOILER A SIDE WATER WALL INTERMITTENT
X0LCQ34AA006
BLOWDOWN MOTORIZED VALVE 6
BOILER FRONT WATER WALL INTERMITTENT
X0LCQ41AA002
BLOWDOWN MAIN MOTORIZED VALVE
BOILER B SIDE WATER WALL INTERMITTENT
X0LCQ42AA002
BLOWDOWN MAIN MOTORIZED VALVE
BOILER REAR WATER WALL INTERMITTENT
X0LCQ43AA002
BLOWDOWN MAIN MOTORIZED VALVE
BOILER A SIDE WATER WALL INTERMITTENT
X0LCQ44AA002
BLOWDOWN MAIN MOTORIZED VALVE

Commissioning Contractor: Date: Operation Contractor: Date:

Contractor: Date: Dongfang Electric: Date:


Appendix 8 Checklist for Control Valve of Steam-Water System
Control Valve Commissioning Record
Feedback corresponding to input value while rising and falling Inspecti
KKS code Description Result Signature Remarks
on date
KKS code Name 0% 25% 50% 75% 100% 75% 50% 25% 0% Result Signature Remarks
Date
BOILER FEED WATER
X0LAB41AA101 BYPASS CONTROL
VALVE
REHEATED STEAM
X0LAF61AA101 EMERGENCY SPRAYING
WATER CONTROL VALVE
A SIDE REHEATED
X0LAF62AA101 STEAM SPRAYING
WATER CONTROL VALVE
B SIDE REHEATED
X0LAF63AA101 STEAM SPRAYING
WATER CONTROL VALVE
BOILER CONTINUOUS
BLOWDOWN FLASH
X0LCQ11AA101
TANK LEVEL CONTROL
VALVE
INTERMITTENT
X0LCQ20AA101 BLOWDOWN PIT INLET
CONTROL VALVE

Commissioning Contractor: Date: Operation Contractor: Date:

Contractor: Date: Dongfang Electric: Date:


PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) 0702-00-M-01-LB-002
DWG No.
PT.PLN(PERSERRO)
PT REKADAYA
JAVA MANAJEMEN
ELEKTRIKA
KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE
ENERGY
SiChuan Electric Power DETAIL
PLTU 1 Jatim-Pacitan
Commissioning & Test DESIGN
(2×315MW) Project
Institute STAGE
Approval Check Procedure of Relief Valve and Steam
Review Design Tightness System
Date SCCTI-TS-GL-C REV
N/A A
Scale DWG No. S-017-2009A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 2 of 18

Table of Contents
1. PURPOSE ........................................................................................................................................... 3
2. SCOPE ................................................................................................................................................ 3
3. PREPARATION BASIS .................................................................................................................... 3
4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .......................................................... 3
5. TOOLS AND INSTRUMENT FOR COMMISSIONING.............................................................. 4
6. PREREQUISITE FOR COMMISSIONING................................................................................... 4
7. MEASURES FOR COMMISSIONING ORGANIZATION .......................................................... 6
8. COMMISSIONING PROCEDURE ................................................................................................. 7
8.1 Steam Tightness Test ............................................................................................................ 7
8.2 Safety relief valve calibration .............................................................................................. 8
8.3 Putting the safety relief valves into operation .................................................................... 10
8.4 Complete trial operation record: ........................................................................................ 10
9. SAFETY MEASURES..................................................................................................................... 11
9.1 Safety Rules for Commissioning........................................................................................ 11
9.2 Personal Risk and Preventative Measures.......................................................................... 11
9.3 Equipment Risk and Preventative Measures ...................................................................... 11
9.4 Safety Precautions.............................................................................................................. 12
10. APPENDIX ............................................................................................................................... 13
10.1 Appendix 1 Commissioning Condition Checklist.............................................................. 14
10.2 Appendix 2 Setting Record of Safety relief Valves and ERV ............................................ 17
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Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 3 of 18

1. Purpose
1.1 The steam tightness test means to have these items completely inspected, such as all heat
surfaces of the boiler proper, steam and water pipelines, headers, all flanges, welding joints,
etc., as well as boiler’s expansion system, stress, displacement and extension of all supports
and hangers to ensure a safe and reliable operation of the unit.
1.2 Since the safety relief valves installed on the drum, superheater, reheater are the important
safeguard facilities for the boiler, the hot state test and regulation for them should be carried
out before the trial operation of the whole set of the boiler to ensure accurate and reliable
action of them needed for safe operation of the unit.

2. Scope
The procedures described herein is applicable to tightness tests for the safety relief valves and
steam system that includes boiler steam tightness test, settings of the safety relief valves for
the drum, superheater and reheater, as well as the ERV trial operation.

3. Preparation Basis
3.1 Summary sheet for set points of safety relief valves and quantity discharged for the boiler;
3.2 Boiler operation manual;
3.3 Manual of boiler performance and structure;
3.4 Instruction manual for installation and maintenance of safety relief valves.

4. Brief Description of System and Equipment


The boiler is to be provided with 12 American Consolidated safety relief valves, of which 3
are for steam drum, 2 for superheater outlet, 4 for reheater inlet, 2 for reheater outlet, and 1
EBV electromagnetic relief valve.
Refer to the table below for the setting of safety relief valves and relief valves:

No. Installation location and No. No. Setting Discharge


Pressure(MPa) (t/h)

1 Steam drum 1# safety relief 1749WB 19.57 272


valve

2 Steam drum 2# safety relief 1749WB 19.96 280


valve

3 Steam drum 3# safety relief 1749WB 20.16 284


valve

4 Superheater outlet 1# safety 1730WD 18.25 114


relief valve

5 Superheater outlet 2# safety 1730WD 18.28 114


relief valve
Superheater outlet
6 electromagnetic relief valve 3538W 154
(ERV) 18.07
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 4 of 18

7 Reheater inlet 1# safety relief 1785WB 4.37 177


valve

8 Reheater inlet 2# safety relief 1785WB 4.37 177


valve

9 Reheater inlet 3# safety relief 1785WB 4.50 182


valve

10 Reheater inlet 4# safety relief 1785WB 4.50 182


valve

11 Reheater outlet 1# safety relief 1765WD 4.01 67


valve

12 Reheater outlet 2# safety relief 1765WD 4.325 72


valve

The information contained in the above list sources form the Instruction Manual of Dongfang
Boiler of DEC (No. 97M-YM)

5. Tools and Instrument for Commissioning


5.1 Walkie talkie;

5.2 Master pressure gauge;

5.3 Hydraulic setting device;


5.4 Tool kit.

6. Prerequisite for Commissioning


Before formally beginning safety relief valve setting and commissioning, commissioning
persons should conduct comprehensive checks on conditions that should be available for
commissioning of this system according to contents listed in Appendix 1 (Commissioning
Condition Checklist) and make well the records.
6.1 Conditions that must be available with machinery provisions
6.1.1 Safety relief valve system
(1) Erection work for all safety relief valves of the system has been completed.
(2) Exhaust steam pipe and silencer have well been fixed and bear a reasonable stress.
Foreign matters inside them have been cleaned away.
(3) The drain pipe of safety relief valves is clear and smooth.
(4) Cold test work for safety relief valves has been completed.
6.1.2 Boiler proper and its auxiliary system
(1) Hydraulic test of boiler is satisfied.
(2) Expansion clearance between relative sections of the boiler has a reasonable value. All
expansion indicators are fully equipped and their zero point at the cold condition has
been set.
(3) Boiler steam-line blowing has been finished.
(4) Commissioning work for all subsystems, such as coal pulverizing, air and flue gas ducts,
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 5 of 18

feed water, fuel oil, ash and cinder removal, etc. has been completed.。
6.1.3 Turbine system
(1) Turbine’s high and low pressure bypass system is ready to be put into regular service.
(2) Shaft jacking and turning system and condenser vacuum system of the turbine are ready
to be put into regular service.
6.2 Conditions that must be available with electrical and I&C
(1) Interlock protection test for the boiler has been completed.
(2) Driving test of electrical and I&C loop for ERV has been completed. All hand-operated
valves have a reliable operation. Pressure switches have been correctly set and are
putting at the calibration state.。
(3) All electrical and I&Cs have been calibrated and have accurate indication.
(4) The master pressure gauges with accuracy class of 0.4 and measuring range of 0-25
MPa and 0-6 MPa have been calibrated for satisfaction and installed.
6.3 Environmental conditions needed
(1) All execution at the commissioning site has been completed with the platform free from
foreign matters and passage should be kept smoothly.
(2) The temporary structure of platform and safety guards needed for safety relief valves
(3) The temporary platform and safety guards for calibration of safety relief valves has been
constructed and prove to be safe and reliable.
(4) The site should have a permanent and sufficient light supply, and some temporary
lighting points shall be added when needed.
(5) There should be complete and reliable communication equipment at the site..
6.4 Other conditions needed
The overall inspection with joint participation of all parties of construction, builder, Owner,
operation, commissioning, etc. should be carried out and any problems discovered should be
solved to make sure that the requirement for the boiler ignition has been met.
(1) All preparation work for the trial operation is completed, and all operators have been
appointed and be qualified through training courses and examinations. The operating
standard and applicable system diagram has examined and approved, and the tools and
forms of operational logs for the operation have been prepared.
(2) Chemicals and materials needed for the trial operation and sufficient chemical water,
fuel oils and coals meeting the design requirement have been well prepared.
(3) Special tool kit for the calibration should be well prepared.
(4) Prepare the tools and materials needed for the maintenance.
(5) Have a sound command organization with definite duties and responsibilities to direct
the trial operation.
(6) The technical information, tools, instrument and the record forms have all been
prepared.
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Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 6 of 18

(7) The personnel of the installation contractor in charge of instrument & control, electrical
and turbine & boiler sections are all presence at the site.
(8) Technical service personnel from the manufacturer of safety relief valves are presence at
the site.

7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows:
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;
◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;


◆ Hold technical disclosure meeting for commissioning;
◆ Organize the commissioning work to be carried out by various parties;
◆ Give instructions to operators in the operation;
◆ Prepare commissioning report.
7.2 Responsibilities of Installation Contractor

◆ Be responsible for individual commissioning of equipment and provide relevant record


and certificate of commissioning;

◆ Be responsible for inspection, maintenance and defect elimination of equipment under


commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;

◆ Be responsible for setup and removal of temporary test platform;

◆ Be responsible for temporary coordination of local I&C components and connection


terminals.
7.3 Responsibilities of Equipment Manufacturers
◆ Representative of manufacturer, if present on the site offering service, shall provide
technical assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator

◆ Prepare tools to be involved in operation;

◆ Prepare operation log and forms;

◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 7 of 18

◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;

◆ Be responsible for dealing with the accidents occurred in commissioning.


7.5 Responsibilities of Dongfang Electric

◆ Be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning;

◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning.


7.6 Responsibilities of Owner
◆ Supervise the execution of commissioning procedures;

◆ Witness the commissioning work;

◆ Accept the results of commissioning.

8. Commissioning Procedure
8.1 Steam Tightness Test
8.1.1 Supply the boiler with feed water to the normal level.
8.1.2 Boiler ignition: Have the boiler ignited and boosted in accordance with the
standard :Operating Code for Boiler.
(1) Rate of temperature and pressure boost should be controlled according to the rules
below:

Pressure of main steam (MPa) <0.98 0.98--3.92 3.92--9.8 9.8--18.2

Rate of temperature rise (℃/h) <28 <56 ≤30 ≤36

Pressure boost rate of (MPa/min) ── ≤0.03 ≤0.05 ≤0.06

(2) The burning and related drain valve opening should be adjusted from time to time
during the period of boiler ignition and pressure boost.
(3) The thermal expansion values at the following conditions and pressure points shall be
recorded: before feed water supplying, after feed water supplying, 0.3~0.5MPa,
1.0~1.5MPa, 5.0~6.0MPa, 9.0~10.0MPa, 12.0~13.0MPa, 14.0~15.0MPa, 16.0~17.40
MPa. If it is found that the normal expansion has been obstructed during above
procedures, stop temperature and pressure boost, and no any operation for further
temperature and pressure boost shall be allowed before the reasons detected and
eliminated. In addition, the special attention should be given to the relative expansion of
wall-type reheater to the water wall and lower section of the boiler.
(4) Manually open the ERV to do the operation test of it and steam exhaust valves of
superheater (reheater). Also carry out the operation test for the control valves of high
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 8 of 18

and low pressure bypass system. The overpressure of the boiler should be avoided
during the continuous pressure boost and any possible accident should be envisioned
and have the countermeasures considered in advance.
(5) When the main steam pressure raised to 10MPa/15MPa, have the boiler proper fully
checked to make sure no any uncommon conditions to be found and then go ahead with
pressure boost.
8.1.3 When the pressure at the outlet of boiler superheater raised to 17.1MPa-17.4MPa, have the
tightness for the superheated steam system tested and have the following items checked by
using the observing and hearing method:
(1) Tightness of welding seams on all pressure containing members of the boiler, man holes,
flanges, etc.;
(2) Tightness of all steam and water valves of the boiler;
(3) Expansion conditions of drum, headers, members of all heat surfaces and steam /water
pipelines within the range of the boiler, as well as the stress conditions of supports,
hangers and their springs.
8.1.4 After the tightness test for the boiler superheat steam system completed, lower the drum
pressure to 15MPa (as requested by the manufacturer) and be ready for the setting of safety
relief valves of the drum and superheater.
8.1.5 After setting of safety relief valves on the drum and superheater, have the outlet pressure of
reheater raised to 3.80-3.81MPa by means of a proper opening of high and low bypass valves
of the turbine to have the tightness of reheat steam system checked.
8.1.6 Have tightness of the reheat steam system tested to have the following items checked by using
the observing and hearing method:
(1) Tightness of welding seams and flanges of reheat steam system;
(2) Tightness of all steam and water pipelines and valves of the reheat steam system;
(3) Expansion conditions of headers, members of all heat surfaces and steam /condensate
drain pipelines, as well as the stress conditions of supports, hangers and their springs.
8.1.7 After the above checks, lower the pressure to 3.5-4.0MPa and have it stabilized to conduct the
calibration of the safety relief valves at inlet and outlet of the reheater.
8.1.8 Conduct real actuating test of safety relief valves of the superheater and reheater system.
8.1.9 If the above test is satisfied have the ERV calibrated, otherwise, have it tested again until it is
satisfied.
8.2 Safety relief valve calibration
8.2.1 Preparation before the test
(1) The master gauges for the setting of safety relief valves (with accuracy class better than
0.4, and one for 0-25WPa, one for 0-6WPa) have well been calibrated and installed.
(2) Have the following items well prepared: tools, hydraulic setting device, string for
pulling the handle, communication equipment, recorder, etc.
8.2.2 For the smooth and safe operation of safety relief valves settings firstly make sure that the
following work have been finished for satisfaction:
(1) The steam tightness test has been passed;
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 9 of 18

(2) The platform, passage, lighting and communication meet the requirement for setting of
safety relief valves and all items needed for the adjustment have well been prepared;
(3) Manually open the ERV to do the operation test of it and steam exhaust valves of
superheater and reheater;
(4) Carry out the operation test for the control valves of high and low pressure bypass
system;
(5) Have the safety relief valves adjusted under the conditions of taking only oil as the fuel
and no coal shall be allowed (or only a little amount of coal);
(6) Have the organization system of “division of responsibilities” set up and every operator
should be present at the site and shall go about their respective items.
8.2.3 The acceptable quality level for calibration of the safety relief valves
(1) Have the actual action proof test for one safety relief valve chosen from each system
after the calibration for all safety relief valves have been completed.
(2) Deviation limit of actual actuating pressure from the designed values shall be ±1%.
(3) The difference between actual re-seating and the popping pressure should be 4%-7% of
the popping one and not more than 10% at most.
8.2.4 Setting procedures for the safety relief valves
The setting of safety relief valves shall be operated sequentially from higher pressure to the
lower ones. Firstly assemble the holddown mechanism for all safety relief valves of drum,
superheater and reheater (except pending ones) and then close the isolation valve at inlet of
EBV valve. Put the safety relief valves, which has well been set, into operation instantly.
(1) Tightness test for the superheated steam system;
(2) Setting of drum’s safety relief valves;
(3) Setting of superheater’s safety relief valves;
(4) Actuating test for the safety relief valves of superheat steam system
(5) Operation test for ERV
(6) Steam tightness test for the reheater system;
(7) Setting of safety relief valves at the inlet of reheater;
(8) Setting of safety relief valves at the outlet of reheater;
(9) Actuating test for safety relief valves of reheater system;
8.2.5 Setting method for the safety relief valves of drum and superheater
(1) Before calibration, lift the lever with help of a tool and let the safety relief valve to be
purged by discharging steam for thirty (30) seconds. After purge release the lever
immediately to check the expansion of steam-discharge tube and other parts of the
safety relief valve, and handle the problems discovered promptly.
(2) Conduct the setting for safety relief valves of drum and superheater by using the
hydraulic setting device.
(3) Maintain a stable combustion of the boiler and adjust the system pressure by using high
and low pressure bypass system to keep the pressure as stable as possible.
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 10 of 18

(4) Setting of safety relief valves and calibration of pressure gauges of DCS shall be based
on the local master gauge.
8.2.6 Actuating test for safety relief valves of the boiler superheater system
(1) Principle for safety relief valve actuating test: the safety relief valve at the outlet of
superheater with the lowest actuating pressure value shall be selected as the subject. The
burning shall be controlled to make the valve returned after the valve popped during the
test. If the tested valve could not be returned for some reason of itself, report the case
immediately and take some measures.
(2) If a slight leak of any safety relief valve discovered in the above test and the system
pressure still maintained then the test could be continued till its end and shut down the
boiler to handle the case.
8.2.7 Operating test of ERV
(1) Contact related department to make ERV energized, open the hand-operated valve at the
inlet of ERV.
(2) When the main steam pressure stepped up to about 15~16MPa, make the ERV popped
by hand to discharge the steam for about thirty (30) seconds and then close it.。
(3) Step up the pressure to the actuating value of ERV to check for a correct one. If the
actual actuating value has a larger deviation from the set point, the pressure control
switch has to be re-calibrated.
8.2.8 Setting of Reheater safety relief valves
(1) Lower the main steam pressure to 8.0~10.0MPa and conduct the setting of safety relief
valves of reheater system by adjusting the pressure of the reheater using the high and
low pressure bypass system.
(2) Before calibration, lift the lever with help of a tool and let the safety relief valve to be
purged by discharging steam for thirty (30) seconds. After purge release the lever
immediately to check the expansion of steam-discharge tube and other parts of the
safety relief valve, and handle the problems promptly if discovered.
(3) Lower the reheater pressure to 3.5~4.0MPa and have it stabilized.
(4) Setting of reheater safety relief valves shall be operated sequentially from higher
pressure to the lower ones, and from one used at the inlet to the one used at the outlet..
8.2.9 Actuating test for the safety relief valves of reheater steam system
(1) Principle for safety relief valve actuating test: the safety relief valve at the outlet of
reheater with the lowest actuating pressure value shall be selected as the subject. The
burning shall be controlled to make the valve returned after it popped during the test. If
the tested valve could not be returned for some reason in itself, report the case
immediately and take some measures.
(2) If a slight leak of any safety relief valve discovered in the above test and the system
pressure still maintained then the test could be continued till its end and shut down the
boiler to handle the case.。
8.3 Putting the safety relief valves into operation
Remove all holding down clips and put all safety relief valves into operation after the
actuating test of them completed and accepted as satisfactory.
8.4 Complete trial operation record:
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 11 of 18

For the setting values of the safety relief valves refer to Appendix 2

9. Safety Measures
9.1 Safety Rules for Commissioning
9.1.1 The parties participating in the commissioning shall be ware of and observe relevant safety
regulations on the site, wear proper clothes and personal safety protection articles.
9.1.2 In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Then investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning shall obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.1.4 The process of temperature rise and pressure boost shall be conducted in accordance with the
related curves for temperature rise and pressure boost.
9.2 Personal Risk and Preventative Measures
‹ The places where the safety relief valves installed
It is possible that the operators might be scalded by steam during procedures of safety
relief valves setting causing a serious injury. To avoid this, the safety isolating measures
should be considered and a skilled operator shall specially be designated to be
responsible for the work. There should be smooth passsage and sufficient lighting
around the safety relief valve, reliable communication facilities and temporary platform
if necessary. Any one who has nothing to do with the work shall be asked to evacuate
the site and any possible accident should be envisioned in advance by operators taking
part in the commissioning.
‹ The pressurized system and pipelines
The hydraulic test for the boiler should be satisfied and any leaks discovered should be
eliminated;
The commissioning of the safety relief valves shall be conducted after the tightness test
for all pipelines completed and prove to be satisfactory.
‹ Equipment damage and/or personal injury caused by over temperature and/ or
overpressure
During the period of safety relief valve commissioning the fuel should be input slowly
and steadily for a stabilized pressure, and overpressure shall be prohibited. Special
attention should be given to the monitoring of wall temperature and the temperature of
the position where the temperature probes have been installed. If the burning rate is out
of control, shut down the boiler immediately. Any possible accident should be
envisioned in advance
9.3 Equipment Risk and Preventative Measures
‹ Malfunction of water level protection
Set the drum level protection inhibited before setting of the safety relief valves to avoid
the boiler’s main protection actuated caused by a false water level during the actuating
test of the safety relief valves.
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 12 of 18

‹ Misoperation for the test


The commissioning of safety relief valves should be operated by the skilled operators.
Have the pressure lowered and the holddown mechanism properly installed before the
test.
‹ Abnormal operation of equipment
If it is found that an operating equipment emits abnormal sound or has other abnormal
condition, and such problem may not be eliminated, stop such equipment and report to
the control rooms immediately.
‹ Equipment damage caused by burning of accumulated coal dust at the tail end
Have the pulverized coal periodically analyzed and keep the coal fineness within the
range specified. Have the combustion carefully adjusted and have the soot blowers for
the air preheater operated uninterruptedly for good burning conditions. Maintain a
normal level and have the closed system purged with a heavy flow of air after the boiler
shutdown. In addition, enhance the monitoring of the flue gas temperature at the boiler’s
tail and handle the problem discovered promptly. Have the ash accumulated at the
boiler’s tail area checked irregularly and have the boiler purged with a large amount of
air before restart. Temporary fire installation shall be equipped at the tail end of the
boiler. Have a special operator monitored and have the fire water system kept at a
serviceable condition.
9.4 Safety Precautions
‹ Oil should be used as the fuel of boiler during the whole procedures of the test to reduce
pressure fluctuation and ensure a stable load of the boiler.
‹ The process of temperature and pressure boost shall be conducted in accordance with
the related curves for temperature and pressure boost to make sure that all heat elements
of the boiler proper expanded freely. Have the temperature difference between upper
and lower walls of the boiler and the temperature of reheater’s metal wall to make sure
that they are within the range of prescribed limit. Strictly limit the temperature of flue
gas at outlet of the furnace under 538℃ for the safe operation of the reheater.
‹ The boiler’s blow-off valve should have a correct action and the high/low bypass
system should be at the hot standby condition during the pressure boost procedures to
keep ready for blowdown when overpressure occurs.
‹ Pay special attention to the safety, any abnormalities shall be reported in time and stop
the temperature and pressure boost to take measures to eliminate them for further
procedures if necessary.
‹ The observing and hearing method shall be used for inspection of the steam system
tightness. Special attention should be paid for prevention of personal injury caused by
leakage of any pressure containing member.
‹ During the period of safety relief valves setting there should be a platform around the
valve firm enough to support three operators. Any one who has nothing to do with the
work shall be asked to evacuate the site.
‹ Since the calibration of safety relief valve belongs to a kind of overhead work, the safety
belt should be used there where the accident of falling from height might occur to avoid
personal injury.
‹ The operator should wear safety hemelt when working at the commissioning site. The
project director should have the site analyzed to eliminate any potential hazard such as
falling from height, electric shock and scald, as well as wringer injury caused by rotary
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Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 13 of 18

machines.
‹ Set the drum level protection inhibited before setting of the safety relief valves to avoid
the actuating of the boiler’s main protection caused by a false level. Pay attention to
avoid the accident of “full of water” and “lack of water” of boiler when the safety relief
valve actuated.
‹ In case of the thrust screw, upper and lower adjustable rings or overlap collars need to
be adjusted the work should be done by the manufacturer’s service man or skilled
operator wearing the protective mask and heat resisting gloves.
‹ In case of any safety relief valve could not be returned after actuating shutdown the
boiler promptly for repair.
‹ Have the auxiliary sootblowing for air preheater operated uninterruptedly and intimately
monitor the temperature of flue gas at the tail end of the boiler.

10. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 14 of 18

10.1 Appendix 1 Commissioning Condition Checklist

No. Items Requirements Result Verified by Remarks


1 Conditions of the turbine and boiler
Installation work of all safety
relief valves in the system □Yes □No
have been finished.
Exhaust steam pipe and
silencer have well been
supported and bear a □Yes □No
reasonable stress. Foreign
(1) Safety relief valve System matters inside them have been
cleaned away.
The drain pipe of safety relief □Yes □No
valves is clear and smooth.
Cold test work for safety
relief valves has been □Yes □No
completed.
Hydraulic test for the boiler is □Yes □No
satisfied.
Expansion clearance between
relative sections of the boiler
has a reasonable value. All □Yes □No
expansion indicators are fully
equipped and set their zero
Boiler Proper and Its point at the cold condition.
(2) Auxiliary System Boiler steam-line blowing has □Yes □No
been finished.
Commissioning work for all
subsystems, such as coal
pulverizing, air and flue gas □Yes □No
ducts, feed water, fuel oil, ash
and cinder handling, etc. has
been completed.
Turbine’s High and low
pressure bypass system is □Yes □No
ready to be put into regular
service
(3) Turbine Section Shaft jacking and turning
system and condenser
vacuum system of the turbine □Yes □No
are ready to be put into
regular service.
2 Electrical and I & C conditions
(1) Interlock and Protection Fulfilled □Yes □No
Driving test of electrical and I
& C loops have been
completed. All hand-operated
(2) ERV valves have a reliable □Yes □No
operation. Pressure switches
have been correctly set and
are putting at the calibration
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 15 of 18

state.
(3) Steam and Water System Electrical and heat power
engineering instrument have □Yes □No
been calibrated and prove to
be accurate.
(4) Master Gauge To be calibrated for □Yes □No
satisfaction
3 Environmental Conditions
(1) Site All work has been completed.
Platform Free of foreign matters. □Yes □No
Passage To be kept smoothly.
(2) Temporary Platform and The construction work
Safeguards finished and prove to be safe □Yes □No
and reliable.
(3) Lighting Sufficient, and temporary
lighting points added when □Yes □No
necessary.
(4) Communication System Reliable □Yes □No
4 Other conditions
(1) Inspection The overall inspection with
joint participation of all
parties of construction,
builder, Owner, operation, □Yes □No
commissioning, etc. should
be carried out and any
problems discovered should
be solved.
(2) Production Preparation Trial operation has well been □Yes □No
prepared.
Operators have well been
trained and have passed the □Yes □No
exam.
The operating standard and
applicable system diagram □Yes □No
has examined and approved.
Tools and forms of
operational logs for the □Yes □No
operation have well been
prepared.
(3) Resources Preparation Chemicals and materials
needed for the trial operation □Yes □No
have well prepared.
Sufficient chemical water,
fuel oils and designed coals □Yes □No
have well been prepared.
(4) Special Tool Kit for the Have well been prepared. □Yes □No
Calibration
(5) Overhaul Tools and Ready for use □Yes □No
Materials
(6) Command Organization To be sound and with definite □Yes □No
for Trail Operation duties and responsibilities.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 16 of 18

(7) The technical information, Ready for use


tools, instrument and the □Yes □No
record forms
(8) Personnel of the In place
installation contractor in
charge of instrument & □Yes □No
control, electrical and
turbine & boiler sections
(9) Technical service In place □Yes □No
personnel from the
manufacturer of safety
relief valves

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 17 of 18

10.2 Appendix 2 Setting Record of Safety relief Valves and ERV

Setting Record of Safety relief Valves and ERV

Drum safety relief valves parameter


Setting pressure
Popping pressure Return pressure
Service Description (MPa) Remarks
(MPa) (MPa)

1 1749WB 19.57
2 1749WB 19.96
3 1749WB 20.16
SH safety relief valves parameter
Setting pressure
Popping pressure Return pressure
Service Description (MPa) Remarks
(MPa) (MPa)

1 1730WD 18.25
2 1730WD 18.28
ERV
Setting pressure Popping pressure Return pressure
Service Description Remarks
(MPa) (MPa) (MPa)
1 3538W 18.07
RH inlet safety relief valves parameter
Setting pressure
Return pressure
Service Description (MPa) Popping pressure(MPa) Remarks
(MPa)

1 1785WB 4.37
2 1785WB 4.37
3 1785WB 4.50
4 1785WB 4.50
RH outlet safety relief valves parameter
Setting pressure Popping pressure Return pressure
Service Description Remarks
(MPa) (MPa) (MPa)
1 1765WD 4.01
2 1765WD 4.325

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Relief Valve and Steam Tightness System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-017-2009A Page 18 of 18
PLTU 1 Jatim-Pacitan (2 × 315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HL-004

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Review Design
Procedure of Cold State Aerodynamic Field
Date Scale N/A DWG No. SCCTI-TS-GL-CS-018-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 2 of 20

Table of Contents

1. PURPOSE ........................................................................................................................................... 3

2. SCOPE ................................................................................................................................................ 3

3. PREPARATION BASIS .................................................................................................................... 3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .......................................................... 3

5. TOOLS AND INSTRUMENT FOR COMMISSIONING.............................................................. 4

6. PREREQUISITE FOR COMMISSIONING................................................................................... 4

7. ORGANIZING MEASURES OF COMMISSIONING .................................................................. 5

8. COMMISSIONING PROCEDURE ................................................................................................. 6

9. SAFETY MEASURES..................................................................................................................... 11

9.1 Safety rules for commissioning...................................................................... 11


9.2 Personal Risk and Preventative Measures ................................................... 11
9.3 Equipment Risk and prevention measures .................................................. 11

10. APPENDIX ............................................................................................................................... 11

Appendix 1 Commission Condition Checklist ........................................................ 12


Appendix 2 Record list of leveling test data for primary air coal pulverized pipe
........................................................................................................................................ 15
Appendix 3 Record list of test parameter for aerodynamic field.......................... 16
Appendix 4 Erection drawing of scaffolding platform for aerodynamic field in
boiler .............................................................................................................................. 19
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Commissioning Procedure of Cold State Aerodynamic Field
Procedure
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1. Purpose
1.1 To master distribution, diffusion and flow conditions of gas in the boiler.
1.2 To understand switching air quantity characteristics of various dampers and resistances of
combustion system and burners.
1.3 To understand size of inscribed circle and gas flow fullness in four-corner firing boiler and
gas flow conditions of burner nozzle.

2. Scope
This Procedure is applicable to commissioning of cold state aerodynamic field. The scope of
commissioning includes:
2.1 Installation, measurement and calibration of burners;
2.2 Adjustment of burner damper;
2.3 Installation of various air speed measuring elements and arrangement of measuring grids in
boiler;
2.4 Calibration of factor for primary air speed-measuring pipe;
2.5 Adjustment and leveling primary air speed, as well as damper characteristic test;
2.6 Secondary air damper characteristic test;
2.7 Test of velocity field in boiler;
2.8 Test of furnace outlet velocity field under various operating conditions;
2.9 Flame tracing test in boiler.

3. Preparation Basis
3.1 Flow chart of flue-gas and air system;
3.2 Schematic diagram of burner structure;
3.3 Manual of combustion equipment;

3.4 Summary Table of boiler thermal design.

4. Brief Description of System and Equipment


In this project, three sub-critical, four-corner tangential firing, natural circulation, steam drum
boilers will be installed. The boiler is of single furnace, semi-outdoor design, lignite, primary
reheating, balanced ventilation and solid deslagging. The model of such boiler is
DG1025/18.3-II13. The combustion equipment is louver-type and horizontal dense-sparse
swing type straight flow burner in manner of four-corner arrangement and tangential firing;
where centerline of burner nozzle is tangent to both virtual circles of furnace center; the
diameters of the two virtual tangential circles are Φ1032mm and Φ548mm respectively; coal
pulverizing system is of medium speed coal mill cooling primary air fan positive pressure
direct firing. The model of coal mill is HP963 and in total fiver coal mills are provided (four
for operating and one for standby); fineness of pulverized coal (R90): Design coal type 32%.
Burner Characteristic Data (design coal type under BMCR)
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 4 of 20

Item Air speed(m/s) Air temperature(℃) Resistance(Pa)


Primary air 28 65 1900
Secondary air 45 346 1000
Perimeter air 35 346 —
Leaked air of furnace — Cold air —

Details will be given after providing the instruction.

5. Tools and Instrument for Commissioning


5.1 Walkie-talkie
5.2 Vibration measurement instrument
5.3 Anemoscope
5.4 Pitot tube
5.5 U-shaped tube
5.6 Emulsion tube
5.7 Sufficient tracing streamer
5.8 Special spanner

6. Prerequisite for Commissioning


Before formally starting system commissioning, commissioning personnel shall carry out
overall inspection on prerequisites for this commissioning listed in Appendix 1
(commissioning prerequisites checklist), and make a proper record.
6.1 Test equipment and material must be checked for a proper condition before test.
6.2 Cold modeling calculation is fulfilled.
6.3 Before test, inspect and measure burner nozzle dimension and mounting angel.
6.4 Air-measuring platform and lightings in boiler and primary air speed leveling platform outside
boiler are installed, accepted and eligible.
6.5 All measuring points for the test have been installed.
6.6 Individual trial operation of forced draft fan, induced air fan and primary air fan is over and
corresponding procedures have been fulfilled.
6.7 Installation and commissioning of flue-gas and air system, pulverized coal pipe and dampers
on pipe are over.
6.8 Air pressure test of furnace and flue-gas and air system is eligible and insulation is over.
6.9 Works for boiler’s flue-gas and air system and coal pulverizing system and in boiler are over;
there has no foreign matter.
6.10 Temperature and pressure measuring elements within flue-gas and air system and furnace
negative pressure measuring elements are tested and eligible; commissioning is over.
6.11 Damper actuation test of coal pulverizing system and flue-gas and air system is over.
6.12 The center in boiler at specified elevation has been fixed with fine wire to show its
PLTU 1 Jatim-Pacitan(2×315MW) Project
REV A
Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 5 of 20

coordinates.
6.13 Burning powder online device is installed and equipment manufacturer has arrived at site and
is prepared for calibration.

7. Organizing Measures of Commissioning


The Procedures shall be carried out under organization of commissioning contractor. Related
units for this project shall closely cooperate each other according to respective responsibilities
and work division, thus to ensure safe and high-efficiency commissioning. See following for
respective responsibilities and work division of various units:
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;

◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;

◆ Hold technical disclosure meeting for commissioning;

◆ Organize the commissioning work to be carried out by various parties;

◆ Give instructions to operators in the operation;

◆ Prepare commissioning report.


7.2 Responsibilities of Installation Contractor
◆ Be responsible for individual commissioning of equipment and provide relevant record
and certificate of commissioning;
◆ Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;

◆ Be responsible for erection and removal of test platform

◆ Be responsible for temporary coordination of local I&Cs and connection terminals.


7.3 Responsibilities of Equipment Manufacturers
◆ Representative of manufacturer, if present on the site offering service, shall provide
technical assistance during equipment commissioning.
7.4 Responsibilities of Operation Department
◆ Prepare tools to be involved in operation;

◆ Prepare operation log and forms;

◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;
◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 6 of 20

◆ Be responsible for dealing with the accidents occurred in commissioning。


7.5 Responsibilities of Dongfang Electric
◆ Be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning。


7.6 Responsibilities of Owner
◆ Supervise the execution of commissioning procedures;

◆ Witness the commissioning work;

◆ Accept the results of commissioning。

8. Commissioning Procedure
8.1 Test Content and Method
8.1.1 Preparation for Testing

(1) Measurement of mounting angle for burners


Before formal test, measure mounting angle for burners and compare it with design
value, and correct it in case of large deviation. The measurement shall be made in
manner of triangular method, namely create a triangle horizontally at the place of
burner nozzle, measure the lengths of various sides, and calculate included angle
between nozzle and water-cooling wall with cosine law, and then determine its
mounting angle.
As shown in Fig. 1, respectively measure the lengths of AB, AC and BC, and
a +b −c
2 2 2
α = arcCosC = − 90
calculate mounting angle with the formula 2ab

Fig. 1 Measurement of mounting angle for burners

(2) Adjustment of burner damper


PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 7 of 20

Adjustment of burner damper includes adjustment of burner secondary dampers:


auxiliary damper, fuel damper and top damper. It requires to achieving same opening
for dampers at same layer, synchronized adjustment, actual opening corresponding to
adjustment command, and even adjustment under commands for various openings.

(3) Fan enabling and air pressure adjustment


After fulfilling above works, start up various rotating machines of flue-gas and air
system, and regulate its pressure and flow, thus to meet the requirements of test
conditions.

(4) Installation and calibration of air speed measuring elements


Install and calibrate air speed measuring device “backrest tube” installed for primary
air pipe. The calibration shall be carried out with standard Pitot tube and electronic
micromanometer. Finally, speed correction factor K of backrest tube will be
measured. Air speed for calibration test shall be within actual operating air speed.

(5) Primary air adjustment and leveling


After installing and calibrating air speed measuring device for primary air pipe, carry
out primary air adjustment and leveling. The leveling shall be carried out as per same
layer, namely fully open dampers at same layer, adjust throttle plate on the
corresponding pipes, thus to achieve same air flow for pipes at same layer and that
flow deviation is within allowable range. The air quantity for adjustment and leveling
shall be within the range for actual operating air speed. Cold state leveling is the basis
of hot state operation. In case of hot state operation, it is still required to further carry
out adjustment and leveling on air quantity of pipes on various layers.

(6) Damper characteristic test


Damper characteristic test includes characteristic test for secondary air damper and
primary air damper of burners. It is purposed to test that whether openings of various
dampers are within 0%~100%; whether burner nozzle air speed is corresponding to
damper opening; each damper shall be subject to test for 5 openings before mapping
out damper characteristic curve finally.
8.2 Formal Test
8.2.1 Measurement of primary air speed
Measurement of primary air speed is purposed to measure air speed of primary air nozzle,
thus to ensure that primary air speed under cold state is within self-modeling zone and
momentum ratio of primary air under cold state and hot state is equivalent. During the test,
primary air pressure and openings of primary and secondary air dampers at various corners
shall be controlled and maintained unchanged.
Calibration factor shall be calculated with following formula:

K=
∑ K p Δ Pi
n Δ Pd
In which:
Kp------- Pitot tube dynamic pressure calibration factor
 Pi------- Dynamic pressure measured at various points with Pitot tube, mmH2O
 Pd------- Dynamic pressure measured with backrest tube, mmH2O
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Commissioning Procedure of Cold State Aerodynamic Field
Procedure
SCCTI-TS-GL-CS-018-2009A Page 8 of 20

n--------- Total number of calibration measuring points


Air speed of secondary air nozzle is obtained through measuring secondary air damper
characteristic curve. Modeling air speed of secondary air nozzle under corresponding
operating conditions is determined according to secondary air damper characteristic curve.
See following for measurement arrangement of secondary air damper characteristic curve.
Table3

#1 corner #2 corner #3 corner #4 corner

Opening of 100% 0% 100% 0%


secondary air
damper 75% 25% 75% 25%
50% 50% 50% 50%
25% 75% 25% 75%
0% 100% 0% 100%

8.2.2 Cold state modeling test


8.2.2.1 Prerequisites for cold state modeling test

(1) Cold modeling air flow’s entering into self-modeling zone


For four-corner arranged burners, critical Reynolds number Re for air flow’s entering
into self-modeling zone shall follow following provisions:
Primary air 1.48×105
Perimeter air 4.8×104
Secondary air 7.5×104
Furnace 7.5×104

(2) Geometrical similarity between the model and actual object


The cold modeling test will be carried out on actual furnace; therefore, the similarity
ratio between the model and actual object shall be 1.

(3) Equivalent momentum ratio for primary air, secondary air and perimeter air under
cold and hot states
Maintain equivalent momentum ratio under cold and hot states and calculate primary
air speed and secondary air speed with following formula:

W1M W10 t 20 + 273


= × (1 + Kμ)
W2M W20 t10 + 273

Calculate the ratio between secondary air speed and perimeter air speed with
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Procedure
SCCTI-TS-GL-CS-018-2009A Page 9 of 20

following formula:

W zj M W zj 0 t 20 + 273
=
W 2 M W 20 t zj 0 + 273
In which:
W10, W20, Wzj0---- Speed of primary air, secondary air and perimeter air
under hot states, m/s;
W1M, W2M, Wzj0------ Speed of primary air, secondary air and perimeter air for
cold modeling, m/s;
t10, t20, tzj0------- Temperature of primary air, secondary air and perimeter
air under hot states, ℃;
K------ Correction factor considering different pulverized coal
flow and air speed, taken as 0.8;
 ------ Weight concentration calculation value for fuel in primary
air: kg (pulverized coal) /kg (air).

(4) Determination of cold state modeling parameter


Simulate burner operating parameter at hot state under various operating conditions:
Table

BMCR BMCR
Operating conditions
Five coal mills Four coal mills
Air speed
operating operating
Air speed of primary air nozzle
28 28
m/s
Air speed of secondary air nozzle
42 45
m/s
Air speed of perimeter air nozzle
35 35
m/s
Concentration of primary air
pulverized coal 0.504 0.630
kg/kg

Air speed of cold state burner nozzle will be as follows when simulate above
conditions:
Table

BMCR BMCR
Five coal mills Four coal mills
operating operating
Air speed of primary air nozzle
18 18
m/s
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Procedure
SCCTI-TS-GL-CS-018-2009A Page 10 of 20

Air speed of secondary air nozzle


26.7 29.2
m/s
Air speed of perimeter air nozzle
20.3 20.1
m/s

8.2.3 Test of cold state velocity field


Allow total air quantity entering into boiler greatly larger than that entering into self-modeling
zone according to control air speed calculated based on cold modeling test principles,

(1) Measurement of velocity field in boiler


Apply iron wire to create cross grid at primary air section in the boiler, and tie a
white cloth strap for every 200mm, and form 64×2=128 measuring points in total.
Measuring speed at various points, including the speed against the wall in boiler. The
circle connecting maximum speed points will be cold modeling tangential circle. The
test shall be carried out under rated operating conditions.

(2) Flame tracing test of aerodynamic field in boiler


When aerodynamic field test is carried out in manner of flame tracing method,
control speed of primary air and secondary air according to requirements in above
table. Mount one special flame on each primary air nozzle and fire it layer by layer,
thus to observe gas flow conditions in boiler.

(3) Test of furnace outlet velocity field


Fix three iron wires at furnace outlet horizontal flue and measure distribution of
velocity field. Airflow residual rotation under different operating conditions will be
assessed according to average speed difference at left and right sides. Total measuring
points for each operating condition shall be 64×3=192 points. Please refer to Table 6
for selection of test condition. Before test of furnace outlet velocity field, remove
scaffolding for the purpose of camera at furnace outlet.
Table 6

Operating
Description
condition
Rated condition, namely pulverized coal for all five layers
#1 input, five coal pulverizing systems operating, top
counter-tangent secondary damper fully open.
Pulverized coal for four layers input, four coal pulverizing
#2 systems operating, top counter-tangent secondary damper fully
open.
Pulverized coal for four layers input, four coal pulverizing
#3 systems operating, top counter-tangent secondary damper fully
open.
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Procedure
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9. Safety Measures
9.1 Safety rules for commissioning
9.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant
safety rules, wear reasonable clothing and appropriate personal protective equipments.
9.1.2 In case of any accidents that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning will obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.2 Personal Risk and Preventative Measures
9.2.1 Before test, ensure all working personnel in furnace, flue, air course and rotating equipment
have been withdrawn.
9.2.3 Guard rail and guard net shall be installed, safety belt worn, and measures taken to prevent
falling or injury by falling object in case of aloft work.
9.2.4 Test platform shall be solid and reliably without shaking and the ladder shall have proper
distance between steps (able to bear the weight of 3-4 adults). Lightings in boiler are efficient
and meet test requirements.
9.3 Equipment Risk and prevention measures
9.3.1 Test equipment and installation equipment shall be effectively isolated.
9.3.2 Power supply and cutoff shall be in strict compliance with related provisions.
9.3.3 The personnel participating in the test shall not operate the equipment to be tested without
authorization. Adjustment of test conditions shall be fulfilled by operation personnel
participating in the test according to predetermined test measures, only after test
superintendent issues the command.
9.3.4 During the test, attention shall be paid to personal and equipment safety. The installation unit
shall assign maintenance personnel to maintain various rotating machines and handle the
problems in time if found; and I&C personnel to dispose and replace in time the transmitter
and instrument with large deviation.
9.3.5 Operation personnel shall carefully monitor, so as to stabilize test conditions as much as
possible. Patrol inspection of operating equipment and system shall be strengthened.
9.3.6 No irrelevant persons at test site. Guard line shall be in place for important rotating machines
and test area.
9.3.7 During test, never allow operating the fan while exceeding rated current, maximum bearing
temperature and maximum vibration.

10. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Procedure
SCCTI-TS-GL-CS-018-2009A Page 12 of 20

Appendix 1 Commission Condition Checklist

Remar
No. Items Requirements Result Verified by
ks

1 Cold modelling calculation Fulfilled □Yes □No

Installation and angle


2 inspection of burner nozzle
Fulfilled □Yes □No

Test platform and lighting Erection fulfilled, accepted and


3 inside and outside the boiler eligible
□Yes □No

4 Measuring point installation Fulfilled □Yes □No

Trial operation of individual


5 fan
Fulfilled and eligible □Yes □No

Installation fulfilled and


6 Damper
eligible upon commissioning
□Yes □No

Test fulfilled and insulation


7 Air pressure test
over
□Yes □No

Metering elements such as Installation fulfilled and


8 pressure, temperature, etc. calibration accurate
□Yes □No

Cleanup of boiler inside and


9 flue-gas and air system
Clean, without foreign matter □Yes □No

Clear road, sufficiency of


10 Field condition
illumination
□Yes □No

11 Communication equipment Usable □Yes □No

12 Fire apparatus Sufficient, convenient for use □Yes □No

Commissioning tools and


13 instruments
Prepared □Yes □No

Commissioning Contractor Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner: Date:
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Procedure
SCCTI-TS-GL-CS-018-2009A Page 13 of 20

Appendix 2 Furnace speed measurement record list

Furnace speed measurement record list

Time

Position Side A Side B

Elevation (mm) 1 2 3 4 1 2 3 4

Commissioning Contractor Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner: Date:
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REV A
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Procedure
SCCTI-TS-GL-CS-018-2009A Page 14 of 20

Appendix 3 Burner nozzle speed measurement record list


Burner nozzle speed measurement record list

Time

Name of Burner Case 1 Case 2 Case 3 Remarks

A1

A2

A3

A4

B1

B2

B3

B4

C1

C2

C3

C4

D1

D2

D3

D4

E1

E2

E3

E4

Commissioning Contractor Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner: Date:
Appendix 2 Record list of leveling test data for primary air coal pulverized pipe
No. Measuring point Measuring point Measuring point Measuring point Measuring point Measuring point Confir Remark
1 (in/out) 2 (in/out) 3 (in/out) 4 (in/out) 5 (in/out) 6 (in/out) med by s
#1 primary air duct
Coal mill #2primary air duct
A #3primary air duct
#4primary air duct
#1 primary air duct
Coal mill #2primary air duct
B #3primary air duct
#4primary air duct
#1 primary air duct
Coal mill #2 primary air duct
C #3 primary air duct
#4 primary air duct
#1 primary air duct
Coal mill #2 primary air duct
D #3 primary air duct
#4 primary air duct
#1 primary air duct
Coal mill #2 primary air duct
E #3 primary air duct
#4 primary air duct

Commissioning Contractor Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner: Date:
Appendix 3 Record list of test parameter for aerodynamic field
No. Item Unit Case 1 Case 2 Case 3 Case 4 Confirmed by: Remarks
1 Furnace draft
2 Temp of flue gas
3 Fixed blade opening of forced draft fan (A/B)
4 Current of forced draft fan (A/B)
5 Outlet pressure of forced draft fan (A/B)
6 Differential pressure of forced draft fan (A/B)
7 Bearing vibration of forced draft fan (A/B)
8 Inlet air temperature of secondary air box side
9 Secondary air temperature of air preheater outlet (A/B)
10 Secondary air temperature of air preheater inlet (A/B)
11 Bearing temperature of forced draft fan (A/B)
12 Secondary air pressure of air preheater outlet (A/B)
13 Secondary air differential pressure of air preheater
inlet/outlet
14 Differential pressure for furnace/ secondary air box side A
15 Differential pressure for furnace/ secondary air box side B
16 Air pressure at secondary air box side
17 Air volume 1 at secondary air box side
18 Inlet air temperature at secondary air box side
19 Air volume 2 at secondary air box side
20 Air temperature at forced draft fan inlet (A/B)
21 Air temperature at forced draft fan outlet (A/B)
22 Motor bearing temperature of forced draft fan (A/B)
23 Motor coil temperature of forced draft fan (A/B)
24 Guide vane opening of primary air fan (A/B)
25 Current of primary air fan (A/B)
26 Outlet pressure of primary air fan (A/B)
27 Differential pressure of primary air fan (A/B)
28 Bearing vibration of primary air fan (A/B)
29 Primary air temperature at air preheater outlet (A/B)
30 Primary air temperature at air preheater outlet (A/B)
31 Bearing temperature of primary air fan (A/B)
32 Primary air pressure at air preheater outlet (A/B)
33 Primary air differential pressure at air preheater inlet/outlet
34 Air temperature at primary air fan inlet (A/B)
35 Air temperature at primary air fan outlet (A/B)
36 Motor bearing temperature of primary air fan (A/B)
37 Motor winding temperature of primary air fan (A/B)
38 Movable blade opening of induced draft fan A
39 Movable blade opening of induced draft fan B
40 Current of induced draft fan A
41 Current of induced draft fan B
42 Inlet pressure of induced draft fan A
43 Inlet pressure of induced draft fan B
44 Inlet/outlet differential pressure of induced draft fan A
45 Inlet/outlet differential pressure of induced draft fan B
46 Bearing vibration of induced draft fan A
47 Bearing vibration of induced draft fan B
48 Bearing temperature of induced draft fan A
49 Bearing temperature of induced draft fan B
50 Motor bearing temperature of induced draft fan A
51 Motor bearing temperature of induced draft fan B
52 Primary air volume of coal mill A
53 Inlet air pressure of coal mill A
54 Outlet/Inlet differential pressure of coal mill A
55 Primary air volume of coal mill B
56 Inlet air pressure of coal mill B
57 Outlet/Inlet differential pressure of coal mill B
58 Primary air volume of coal mill C
59 Inlet air pressure of coal mill C
60 Outlet/Inlet differential pressure of coal mill C
61 Primary air volume of coal mill D
62 Inlet air pressure of coal mill D
63 Outlet/Inlet differential pressure of coal mill D
64 Primary air volume of coal mill E
65 Inlet air pressure of coal mill E
66 Outlet/Inlet differential pressure of coal mill E

Commissioning Contractor Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner: Date:
Appendix 4 Erection drawing of scaffolding platform for aerodynamic field in boiler

See following for attached figure:

Burner
燃烧器

23100

19600
Grid
网格铁丝wire
18100
Stay
拉线螺母nut
Grid 网格截面
section
Scaffold
脚手架踏板
step
脚手架踏板
Scaffold step

12600

Burner燃烧器喷口
nozzle

1000mm

100mm Grid
网格铁丝 wire 150mm gap between steps at this point
此处踏板间隙150mm

Manhole
人孔
Coordinat
e坐标灯
lamp Coordinate
坐标灯 lamp
Scaffold
脚手架踏板 step
Scaffold
脚手架
600×1000mm
Description of erection of scaffold in boiler (for cold state aerodynamic field test)
1) At the section 1.5m below lower primary air nozzle and the section of burner isolated area, the
gang board shall be provided along the periphery of furnace; in addition, cross type gang boards
shall be set up at the lower layer section along furnace center, and platform and climbing gang
board shall be set up at 12.6m manhole, up to upper layer scaffolding platform. Please refer to
schematic drawings. All platform gang boards shall be mounted with guardrail at the outer side.
The width of gang board shall be 1m;
2) At the manhole section after horizontal flue final stage reheater at furnace exit, two layers
furnace-through gang boards shall be set up, and at the section of windward side, it shall be
provided with three layers of soldering iron wires (connected through nuts). Please refer to
schematic drawings. All platform gang boards shall be mounted with guardrail at the outer side.
3) At the manhole section after horizontal flue final stage reheater at furnace exit, gang boards shall
be set up and introduced to middle of flue; in addition, in-boiler camera platform shall be set up at
platen superheater in the middle of furnace. The platform shall be about 1.5m wide and gang
board shall be set up safely and securely; in addition, it requires that about 150mm gap shall be
reserved in the middle, for the purpose of video recording. All platform gang boards shall be
mounted with guardrail at the outer side.
4) Scaffolds shall be set up nearby corner burners at windward side. The scaffolds shall be positioned
in such ways, thus to be suitable for climbing of test personnel and not to block burner nozzle. The
inner section of scaffolds shall be 600×1000mm. The distance from edge to nozzle shall be
1000mm. Please refer to schematic drawings.
5) Four nuts (or iron hooks) shall be welded at furnace-surrounding water-cooling wall center at
lower primary air nozzle section, for connecting the iron grid. In addition, the iron wire shall be
connected at the place of 100mm from water-cooling wall, for measuring air speed against the
wall. Please refer to schematic drawings.
6) Please refer to schematic drawings for mounting of coordinate lamp. The coordinate lamp shall be
applied with portable lamp and fixed with #8 iron wires, to prevent from blowing away by strong
wind.
PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-G-01-H-001

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power DESIGN STAGE
PLTU 1 Jatim-Pacitan (2×315MW)
Commissioning & Test Institute
Project
Approval Check Procedure of Energy Source and Resource
Review Design Economizing
Date Scale N/A DWG No. SCCTI-TS-GL-CS-001-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 2 of 8

Table of Contents

1 PURPOSE ......................................................................................................................................................... 3

2. SCOPE .............................................................................................................................................................. 3

3. PREPARATION BASIS .................................................................................................................................. 3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT ........................................................................ 3

5. TOOLS AND INSTRUMENT FOR COMMISSIONING............................................................................ 4

6. MEASURES FOR COMMISSIONING ORGANIZATION ........................................................................ 4

7. TECHNICAL MEASURES............................................................................................................................. 5

8 DIVISION OF STAGES AND OIL CONSUMPTION CRITERIA............................................................. 7

9. OIL CONSUMPTION CRITERIA AND NOTES......................................................................................... 7

10. VERIFICATION OF ACTUAL FUEL OIL CONSUMPTION.................................................................... 7

11. SAFETY MEASURES..................................................................................................................................... 7

11.1 Safety rules for commissioning .......................................................................... 8

11.2 Personal Risk and Preventative Measures.......................................................... 8

11.3 Equipment Risk and Preventative Measures ...................................................... 8


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 3 of 8

1 Purpose
1.1 To save strategic energy sources of the country and reduce the investment in the project.
1.2 To examine the unit design level, manufacture and installation quality, commissioning plans,
organization and management levels, and plant operators’ skill indirectly
1.3 To promote the cost-saving awareness of the employees of all associated parties.

2. Scope

This Procedure is a scheme for energy source and resource saving. The scope of
commissioning associated with this scheme include four stages, namely boiler pickling,
ignition and pipe blowing, unit synchronization with power grids, load operation and 30day
reliability trial run.

3. Preparation Basis
3.1 Startup and commissioning plans for PLTU 1 Jatim-Pacitan (2×315MW) Power Plant
3.2 Instruction manuals for combustion equipments of the boilers;
3.3 Boiler operation manual

4. Brief Description of System and Equipment


4.1 Two sets of natural circulation drum boilers with subcritical parameter and four corner
tangential firing are provided in this project. It has single furnace with half open arrangement
of II Type, brown coal fired, single reheating, balanced ventilation, solid slag removing, all
steel structure and with metal rain shed on furnace top. All these three boilers are designed
and manufactured by Dongfang Boiler Group Co,. Ltd. Boiler model: DG1025/17.4-II13. The
firing mode in furnace is a positive, direct blowing, four-corner tangential firing with swing of
burner nozzles. For the steam temperature of super heated steam, the water spray temperature
reducer with I,II and III steps is provided for the adjustment of temperature and the
arrangement of three steps and five points is provided. The swinging burner nozzle is used as
the main way to adjust the steam temperature of the reheated steam, reducing temperature
with water spray as auxiliary and spray temperature reducers are provided as well.
4.2 Main Parameters of Boiler (Design type of coal)

BMCR
Item Unit ECR condition
condition

work pressure of boiler drum MPa 18.77 18.58


flow of superheated steam t/h 1025 976.2
outlet pressure of superheated steam MPa 17.4 17.32
outlet temperature of superheated steam ℃ 541 541
flow of reheated steam t/h 839.4 802
inlet/outlet pressure of reheated steam MPa 3.76/3.58 3.59/3.41
inlet/outlet temperature of reheated steam ℃ 329/541 324/541
Temp. of feed water ℃ 281 278
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 4 of 8

Temp of flue gas ℃ 131 131


Outlet flue gas temp. of furnace ℃ 985 994
Inlet air temp. of APH ℃ 30 30
Outlet air temp. of APH ℃ 359/351 359/351
calculated consumption of boiler fuel t/h 161.58 154.23
calculated efficiency of boiler % 93.26 93.71

4.3 Swing burners are adopted as burners which are arranged in four corners and double
tangential firing is formed in the furnace and the presumed tangential are ф548mm and
ф1032mm respectively. The horizontal bias burning technique in the design of pulverized coal
nozzles is used to strengthen the stability of combustion in boiler when running with low load.

Feature Data of Burner (design coal type/BMCR load)

Air-to Coal Air Flowrate Air Temperature Resistance


No. Item
Ratio (%) (m/s) (℃) (Pa)
1 Primary air 28 65 1900
2 Secondary air 45 346 1000
3 Surrounding air 35 346 ——
Furnace air
4
leakage
Details will be given after providing the instruction.

5. Tools and Instrument for Commissioning


5.1 Walkie talkie;
5.2 Fuel oil meters

6. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows:
6.1 Responsibilities of Commissioning Contractor

◆ `Preparation and revision of commissioning procedures;

◆ `Preparation of commissioning plan;

◆ `Preparation of instruments and equipment required for commissioning;

◆ `Hold technical clarification meeting for commissioning;

◆ `Organize the commissioning work to be carried out by various parties;

◆ `Give instructions to operators in the operation;

◆ `Prepare commissioning report.


6.2 Responsibilities of Installation Contractor
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 5 of 8

◆ Be responsible for individual commissioning of equipment and provide relevant record


and certificate of commissioning;

◆ Be responsible for inspection, maintenance and defect elimination of equipment under


commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;

◆ Be responsible for temporary coordination of local control and instruments and


connection terminals.
6.3 Responsibilities of Equipment Manufacturers

◆ Representative of manufacturer, if present on the site offering service, shall provide


technical assistance during equipment commissioning.
6.4 Responsibilities of Plant Operator
◆ Prepare tools to be involved in operation;

◆ Prepare operation log and forms;

◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;

◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;

◆ Be responsible for dealing with the accidents occurred in commissioning。


6.5 Responsibilities of Dongfang Electric

◆ Be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.

◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning.


6.6 Responsibilities of Owner

◆ Supervise the execution of commissioning procedures;

◆ Witness the commissioning work;

◆ Accept the results of commissioning。

7. Technical Measures
7.1 The oil for commissioning shall be saved based on the condition that personal and equipment
safety can be guaranteed and commissioning quality specified for each commissioning stage
can be assured.
7.2 The fuel oil meters (flow meters) have been adjusted and calibrated and ready for use prior to
ignition and confirmed by all associated parties. The initial values of these meters shall be
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 6 of 8

recorded.
7.3 The fuel oil systems shall be purged with steam and oil circulation shall be performed 96
hours before ignition. It is allowed to ignite burners only after confirming that the filter
screens are clean, in order to prevent oil guns from being clogged and poor atomization.
7.4 Pay special attention to cold-state inspection and preventative test activities in order to
identify and eliminate any possible problem and defects regard to the design, construction and
equipments, minimize the number of boiler shutdown during commissioning and therefore
save fuel oil.
7.5 Carefully carry out inspection for damper baffle of boiler, flue air & air duct cleaning and
inspection, cold-state air test, oil nozzle inspection, cold-state burner inspection, cold-state
steam &water valve inspection, cold-state inspection and test for ST and boiler protection and
cold-state startup test and inspection for pulverizing plants.
7.6 Ensure that feedwater quality conforms to the design requirements, carefully flush boiler and
feedwater piping and ignite burners only after the boiler water quality is acceptable, and
minimize the blowdown rate.
7.7 Commission the deaerators in advance to increase feedwater temperature and reduce fuel oil
consumption.
7.8 Test the regulation characteristics of feedwater and desuperheating water regulating valves at
cold state to ensure that the relevant automatic systems can be put into operation as soon as
possible and fuel oil can be saved.
7.9 `During commissioning, the design coal shall be fired and industrial analysis of boiler coal
shall be carried out on a daily basis. One copy of coal quality analysis report shall be
submitted to the commissioning team on a daily basis.
7.10 The HP and LP heaters shall be put into operation as soon as possible. The oil consumption
for stable combustion shall be reduced as possible after two sets of pulverizing plants are put
into operation.
7.11 Oil guns shall be used in effective and reasonable manner according to actual operating
conditions of the units and plans, the number of oil guns in use shall be increased or decreased
on a timely basis and only necessary number of oil guns shall be put into operation.
7.12 Operators shall adjust combustion on a timely basis, raise furnace temperature as soon as
possible. Operators shall cut off fuel oil supply and allow the units to operate fully on coal
after the boiler load reaches 70% rated load (temporarily determined), boilers attain stable
combustion and fire protective measures have been taken.
7.13 After the boilers start up, open drain valves as soon as possible and warm up piping to speed
up warming prior to steaming to turbines. During hot startup, adjust the HP&LP bypass valve
opening on a timely basis to increase steam temperature, drive steam turbines as soon as
possible and save fuel oil.
7.14 Before the steam turbines are driven, prepare for electrical startup test. The tests shall be
instructed on a unified basis to ensure safety. If no major problem affecting unit load increase
exists after the units are connected with power grid and overspeed test has been conducted,
allow the unit to operate under large load according to the load curve in order to exhibit any
possible defect and prepare for 30 day trial run stage.
7.15 The operators of turbines, boilers, electrical, chemical, I&C, fuel and handling systems shall
obey the uniform instruction, communicate with each other from time to time, and do well in
various preparatory works to prevent time delay and unnecessary fuel oil consumption.
7.16 The leaders shall provide proper instruction and shift supervisors shall arrange for water, coal,
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 7 of 8

electric power, oil, steam and chemical product supply and dispatching and communication
works, and prepare for the test in all regards in order that the trial run activities can be carried
out smoothly and continuously and boilers don’t consume fuel oil unnecessarily.
7.18 All professionals shall carefully operate, adjust and maintain equipments, prevent accident,
damage to equipments and boiler and unit shutdown, and minimize the number of startup,
otherwise, the project will be delayed and fuel oil will be consumed unnecessarily.
7.19 The maintenance personnel shall make all preparation and tools, materials and persons must
be in place. Any abnormal condition must be repaired and inspected, and safety measures
shall be in place and maintenance time shall be shorted to reduce oil consumption. In case a
major equipment accident occurs and it is impossible to repair such trouble within a short time
and carry out other commissioning activities, the boilers shall be shut down immediately.
7.20 In order to save fuel oil, an employee shall be assigned to calculate oil consummation at
various stages and report to the trial run leading team.

8 Division of Stages and Oil Consumption Criteria


Commissioning stage Oil Consumption Planned (T)
Ignition and piping blowing 3000
Connection with power grid and operation under load 2000
30-day reliability test 1500
Total 6500

9. Oil Consumption Criteria and Notes


The oil consumption criterion of Unit 1 is 6,500 tons calculated from initial ignition and
piping blowing to the completion of 30 day reliability trial operation.

10. Verification of Actual Fuel Oil Consumption


10.1 Strictly verify and record the amount of oil supply to the oil depot
10.2 Record oil level in the depot per 2 hours when the boilers consume fuel oil, per shift when the
boiler does not use fuel oil. When oil is made up to the depot, the makeup amount and time
shall be recorded and the signature of the persons accepting fuel oil shall be available.
10.3 During boiler operation, operators shall record oil level difference and makeup amount of the
depot per shift and record the time when each oil gun is put into use.
10.4 The oil flow meters shall be used and initial reading of the meters and various operating
values as well as the difference between oil supply and return amount shall be recorded. After
the oil flow meter is used, the meter bypass valve shall be opened with the approval of the
commissioning leading team.
10.5 The boiler commissioning personnel shall calculate and verify oil consumption according to
the above information and report to the trial run leading team.
10.6 It is strictly prohibited to practice fraud.
10.7 Fuel oil consumption for use by the startup boilers shall not be considered.

11. Safety Measures


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Energy Source and Resource Economizing REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-001-2009A Page 8 of 8

11.1 Safety rules for commissioning


11.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant
safety rules, wear reasonable clothing and appropriate personal protective equipments.
11.1.2 In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Investigate the cause and take corrective measures.
11.1.3 The parties participating in the commissioning will obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
11.2 Personal Risk and Preventative Measures
11.2.1 Injuries might be caused by rotating equipment during commissioning or test. Therefore,
special care must be taken during work and do not touch the rotating components with tools
or your hand.
11.3 Equipment Risk and Preventative Measures
11.3.1 Before fuel oil supply stops, the unit operation and boiler combustion shall remain stable.
PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-G-01-H-002

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Review Design Procedure of Boiler Integral Start-up
Date Scale N/A DWG No. SCCTI-TS-GL-CS-002-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 2 of 28

Table of Contents

1. PURPOSE ............................................................................................................................................ 3

2. SCOPE ................................................................................................................................................. 3

3. PREPARATION BASIS....................................................................................................................... 3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT ............................................................... 3

5. TOOLS AND INSTRUMENT FOR COMMISSIONING................................................................... 5

6. PREREQUISITE FOR COMMISSIONING ....................................................................................... 5

7. MEASURES FOR COMMISSIONING ORGANIZATION ............................................................... 8

8. COMMISSIONING PROCEDURE .................................................................................................... 9

9. SAFETY MEASURES ...................................................................................................................... 15

9.1 Safety rules for commissioning ........................................................................ 15


9.2 Personal Risk and Preventative Measures........................................................ 15
9.3 Equipment Risk and Preventative Measures .................................................... 15

10. APPENDIX................................................................................................................................ 17

Appendix 1 Integral Startup Condition Checklist .......................................................... 18


Appendix 2 Boiler Commissioning Parameter Record .................................................. 22
Appendix 3 Commissioning Parameter Record for Pulverizing Plants ......................... 23
Appendix 4 Record for Boiler MFT (OFT) and Integral Interlock Test......................... 24
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 3 of 28

1. Purpose
The unit integral startup is one major process of unit commissioning which is associated with
safety and quality of unit startup and project completion etc. Through it, various
performances of the units may be evaluated on a comprehensive basis. In order to guide
boiler integral startup and commissioning and ensure safe and normal unit operation, this
procedure has been prepared. During boiler integral startup, the previously-made
commissioning of various subsystems can be also examined.

2. Scope
This procedure is applicable to integral startup and commissioning. The following systems
need be commissioned:
2.1 Main steam and reheat steam systems;
2.2 Feedwater and desuperheating water systems;
2.3 Water drain& drainage, vent and blowdown systems;
2.4 Fuel oil and ignition system;
2.5 Flue-gas and air system;
2.6 Pulverizing plant;
2.7 Air preheater system;
2.8 Ash blowing systems
2.9 Furnace flame monitor system;
2.9 Other systems.

3. Preparation Basis
3.1 Startup and commissioning plans for PLTU 1 Jatim-Pacitan (2×315MW) Power Plant
3.2 Engineering documents associated with PLTU 1 Jatim-Pacitan (2×315MW) Power Plant.
(1) Thermal system diagram provided by the design institute;
(2) Pulverizing plant diagram provided by the design institute;
(3) Manual of boiler performance and structure;
(4) Boiler erection manual;
(5) Boiler operation manual;
(6) Manual of combustion equipment.

4. Brief Description of System and Equipment


4.1 Two sets of natural circulation drum boilers with subcritical parameter and four-corner
tangential firing are provided in this project. It has single furnace with half open arrangement
of II Type, brown coal fired, single reheating, balanced ventilation, solid slag removing, all
steel structure and with metal rain shed on furnace top. All these two boilers are designed and
manufactured by Dongfang Boiler Group Co,. Ltd. Boiler model:DG1025/17.4-II13.The
firing mode in furnace is a positive, direct blowing, four corner tangential firing with swing
of burner nozzles. Superheated steam temperature is adjusted by Stage 1, 2 and 3 spray type
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 4 of 28

desuperheaters. Three stages and five points are arranged in total. The swinging of burner
nozzle is used as the main way to adjust the steam temperature of the reheated steam,
reducing temperature with water spray as auxiliary and spray temperature reducers are
provided as well.
4.2 Main Parameters of Boiler (Design type of coal)

单位 BMCR BRL
Description
Unit BMCR BRL
flow of superheated steam t/h 1025 959.2
Superheated steam pressure MPa 17.40 17.26
Superheated steam temperature ℃ 541 541
Temp. of feed water ℃ 280 275
flow of reheated steam t/h 841 785.7
(inlet/outlet) MPa 3.80/3.63 3.55/3.39
(inlet/outlet) ℃ 330/541 322/541
Drum pressure MPa 18.77 18.42
Desuperheating water flow at stage 1 desuperheater t/h 19.41 27.03
Desuperheating water flow at stage 2 desuperheater t/h 4.85 6.76
Reheater water spray flow t/h 6.54 4.66
Outlet flue gas temp. of furnace ℃ 987 989
Flue gas temperature at HP reheater outlet ℃ 806 806
Flue gas temperature at HP superheater outlet ℃ 732 731
Flue gas temperature at LP superheater outlet ℃ 438 438
Flue gas temperature at economizer outlet ℃ 388 387
Exhaust gas temperature (corrected) ℃ 134 136
Air preheater inlet temperature ℃ 30 30
Air preheater outlet temperature
℃ 363/355 364/356
(primary /secondary)
Fuel consumption t/h 163.91 155.28
Boiler efficiency % 93.04 92.94

4.3 Swing burners are adopted as burners which are arranged in four corners and double
tangential firing is formed in the furnace and the presumed tangential are ф548mm and
ф1032mm respectively. The horizontal bias burning technique in the design of pulverized
coal nozzles is used to strengthen the stability of combustion in boiler when running with low
load.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 5 of 28

Feature Data of Burner (design coal type/BMCR load)

Air
Air-to coal Air Flowrate Temperature Resistance
No. Item
Ratio (%) (m/s) (Pa)
(℃)
1 primary airc -- 28 65 1900
2 secondary air -- 45 346 1000
3 Surrounding air -- 35 346 --
4 Furnace air leakage -- -- -- --

4.4 Features of Fuel as below:

煤种
Worst Range of
No. Item Symbol Unit DSG'D Coal Change in
Coal Type Coal Quality
type
Carbon content as received
1 Car % 47.65 45.2 41.25~49.4
basis
2 As-received basis hydorgen Har % 3.36 3.15 3.375~4.55
3 As-received basis oxygen Oar % 14.49 11.7 7~16.25
4 As-received basis nitrogen Nar % 0.77 0.70 0.375~0.975
5 As-received basis sulfer Sar % 0.23 0.25 0.1~0.23
6 As received basis ash content Aar % 3.5 4 3~6
As received basis total
7 Mar % 30 35 25~35
moisture
Water content as air dried
8 Mad % 20 25 15~25
basis
Dry ash-free basis volatile
9 Vdaf % 50 46 42~67.8
component
Fixed carbon content as
10 FCar % 30 -- 28~42
received basis
Low heat value as received KCal
11 Qnet,ar 4200 3900 3900~4500
basis /kg
12 Grindability coefficient HGI 45 45 45-65
13 Fineness of pulverized coal R90 32
14 Ash fusing point
(1) Deformation temperature DT °C 1150 1150 1150
(2) Softening temperature ST °C 1200 1200 1200
(3) Fusion temperature FT °C 1300 1300 1300

5. Tools and Instrument for Commissioning


5.1 Walkie talkie;
5.2 Handheld vibration measurement instrument;
5.3 Digital multimeter;
5.4 Infrared themodetector.

6. Prerequisite for Commissioning


Before formally beginning integral startup commissioning job, commissioning persons
should conduct comprehensive checks on conditions that should be available for
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commissioning of this system according to contents listed in Annex 1 (Integral startup and
Commissioning Condition Checklist) and make well the records.
6.1 Conditions that must be available with machinery provisions
6.1.1 Boiler proper: The installation and insulation works are complete. The hydrostatic test and air
pressure test have been completed. Scaffolds, litter and foreign matters have been removed
from furnace and flue gas& air ducts, all personnel have escaped and all manholes and access
holes have been closed.
6.1.2 Flue gas and air systems: The installation and insulation works are complete. Commissioning
of induced draft fans, forced draft fans, primary fans and air preheaters are complete.
6.1.3 Steam and water systems: the installation and insulation are complete, all supports and
hangers are complete, pins have been removed from spring hangers and the entire systems
have been checked and accepted. The blind plates for hydrostatic test have been removed.
6.1.4 Fuel oil systems: the installation and insulation are complete and trail run of various oil
pumps have been successfully completed. The oil piping has been purged with steam.
6.1.5 Pulverizing plant: The installation and insulation works are complete. Static commissioning
of coal mills and feeders are complete. Individual commissioning of coal mills and feeder and
auxiliary facilities are complete.
6.1.6 Coal handling systems: the installation is complete and trail run of various auxiliary facilities
have been successfully completed. Adequate design coal has been prepared and it is ready to
feed coal to coal bunkers. The raw coal bunkers have been thoroughly cleaned.
6.1.7 Electrostatic precipitator systems: the installation and insulation are complete, voltage rising
and rapping tests are finished and the entire systems have been checked and accepted. All
electrostatic precipitators and economizer ash bunkers have been thoroughly cleaned and
ready for operation.
6.1.8 Ash and cinder handling system: The installation and insulation works are complete.
Individual trial run of various auxiliary facilities has been completed and the systems are
ready for operation.
6.1.9 Flame scanning cooling air system: the installation is complete and flame scanning cooling
fans have been commissioned.
6.1.10 Ash blowing systems; the installation and insulation are complete and the piping has been
purged with steam. Static commissioning of all ash blowers has been successfully completed.
The systems are ready for operation.
6.1.11 Auxiliary systems: the dosing, sampling, periodic blowdown, continuous blowdown, drain,
vent, back-flushing and inert gas flushing systems have been installed and insulated.
6.1.12 Bottom steam heating system: the installation and insulation are complete and the systems are
ready for operation.
6.1.13 Expansion systems: all expansion indicators have been installed as per the design and reset to
zero point. All parties confirm that no expansion is restricted.
6.1.14 Fire protection system: Adequate fire fighting equipments are in place. Fire water (steam)
systems are ready for use.
6.2 Conditions that must be available with electrical and I&C
6.2.1 Static commissioning of all motor-driven valves, pneumatic valves and dampers are complete
and the valves and dampers are able to move freely under remote control.
6.2.2 Static commissioning of all alarm systems are complete and correct indication is given on all
alarm windows.
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6.2.3 The emergency pushbuttons of all driving machineries are functional and wired correctly.
Simulation operation indicates that they are in good order.
6.2.4 Commissioning of the PLC systems for auxiliaries is complete, the startup and shutdown
logic of the PLC controllers are correct and the equipments can operate normally.
(1) Startup condition of the oil lubrication stations of fans

(2) Interlock relations of oil pumps;

(3) Startup and shutdown conditions and interlock relations of induced draft fans, forced
draft fans and primary fans
(4) Interlock relations between dampers;

(5) Program-based startup and shutdown test for all fans.


6.2.5 Static FSSS commissioning is complete. The interlock logic is correct and movement is
reliable.
(1) Furnace purging permissive;

(2) MFT conditions and interlocked operation after MFT is active;

(3) OFT conditions and interlocked operation after OFT is active;

(4) Oil gun ignition permissive;

(5) Oil gun startup and shutdown under program control;

(6) Oil gun trip conditions;

(7) Coal ignition permissive;

(8) Coal mill& feeder startup permissive;

(9) Coal mill startup and shutdown conditions.


6.2.6 Static commissioning of the data acquisition system is complete and the name and indication
of all data points are correct.
6.2.7 Static commissioning of the industrial CCTV systems and flame scanning systems have been
completed and they are ready for operation at any time.
6.2.8 Static commissioning of coal feeder weighing systems is complete and the systems are able to
measure and indicate weights. .
6.2.9 Static commissioning and setting of furnace flue gas temperature probe is complete and the
probe can move freely.
6.2.10 The static commissioning of ash blower and periodic blowdown PLCs has been successfully
completed and simulation tests indicate that the relations are correct and movement is
reliable.
6.2.11 The interlock and simulation tests have been performed upon turbines, boilers and generators.
The test shows that the interlock is correct and operation is reliable.
6.3 Conditions that must be available with civil construction
6.3.1 The roads within the commissioning site must be free of obstructions. There is adequate
lighting and reliable emergency illumination.
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6.3.2 Communication equipments at trial operation site are convenient and ready for use, and
adequate fire fighting equipment and materials are provided.
6.4 Commissioning items which should be completed
6.4.1 The boiler proper has been pickled, the boiler front-end systems have been washed with
alkaline and temporary systems have been removed.
6.4.2 The operation tests show that flue gas &air dampers, steam& water valves of boilers and
dampers of pulverizing plants can move normally. The valves can move freely in correct
direction and be fully closed and opened;
6.4.3 Boiler cold-state ventilation test is complete; Primary air leveling and flow calibration are
complete.
6.4.4 The boiler piping has been blown. The temporary systems haven been removed.
6.4.5 The sequential control system (SCS) of boiler auxiliaries has been checked and tested;
6.4.6 The furnace safety supervision system (FSSS) has been checked and tested;
6.4.7 The emergency pushbuttons of various rotating machineries have been checked and tested.
6.4.8 All alarm signals have been checked and tested.
6.5 Other Necessary Conditions
6.5.1 The chemical water systems are functional and ready to supply conforming demineralized
water.
6.5.2 The compressed air systems are functional and ready to supply conforming compressed air;.
6.5.3 The station service system is functional and able to supply power and cut off power supply
according to the requirements.
6.5.4 The lighting and communication systems of the power plant are functional and ready for use
at any time.
6.5.5 The central air conditioning system has been commissioned, functional and ready for use at
any time.

7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows:
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;

◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;

◆ Hold technical clarification meeting for commissioning;

◆ Organize the commissioning work to be carried out by various parties;

◆ Give instructions to operators in the operation;

◆ Prepare commissioning report.


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7.2 Responsibilities of Installation Contractor


◆ Be responsible for individual commissioning of equipment and provide relevant record
and certificate of commissioning;
◆ Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;


◆ Be responsible for temporary coordination of local control and instruments and
connection terminals.
7.3 Responsibilities of Equipment Manufacturer
◆ Representative of manufacturer, if present on the site offering service, shall provide
technical assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator
◆ Prepare tools to be involved in operation;
◆ Prepare operation log and forms;
◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;
◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;
◆ Be responsible for dealing with the accidents occurred in commissioning。
7.5 Responsibilities of Dongfang Electric
◆ Be responsible for supervision and control over commissioning work;
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;
◆ Organize analysis and settlement of major technical issues in commissioning。
7.6 Responsibilities of the Owner
◆ Supervise the execution of commissioning procedures;
◆ Witness the commissioning work;
◆ Accept the results of commissioning。

8. Commissioning Procedure
8.1 Preparation Prior to Boiler Startup, and Ignition and Flushing Stage
8.1.1 Check and Confirmation of Flue Gas &Air Dampers and Steam &Water Valves
Check and confirm that all flue gas &air dampers and steam &water valves are able to move
freely in correct direction and fully opened and closed to their limit positions. The status
indication is correct.
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For the Flue Gas & Air Damper Checklist, refer to the Fan Commissioning Procedures of the
relevant rotating machineries.
For the Steam & Water Valves Checklist, refer to the Piping Blowing Commissioning
Procedures.
8.1.2 Cold ventilation test of boiler
For primary air leveling and flow calibration, refer to Boiler Cold-state Ventilation
Commissioning Procedure.
8.1.3 Check and Test of Interlock, Protection, Sequential Control and Alarm for Rotating
Machineries
Check and test of sequential control system (SCS) of boiler auxiliaries
Check and operation test of emergency pushbuttons of various rotating machineries.
All audible and visual alarm signals have been checked and tested.
Refer to the Fan Commissioning Procedure of the relevant rotating machineries for details.
8.1.4 Check and Test of the FSSS (note: the interlock and protection test items shall be based on the
result of logic discussion)
Check and test furnace purging conditions;
Check and test the result occurring after the MFT is active.
Interlock test covering the turbine, boilers and electrical systems
For details, refer to Appendix 4.
8.1.5 Boiler piping blowing. For details, refer to the Piping Blowing Commissioning Procedure.
8.1.6 Check and test of pulverizing plants. For details, refer to the Pulverizing Plant Startup and
Commissioning Procedure.
8.1.7 Check and test of ash and cinder handling system. Refer to Commissioning Procedure for Ash
and Cinder Handling System for detail.
8.1.8 Static Check and Commissioning of Ash Blower Systems
Check the ash blower system piping, including expansion, supports and hangers.
Check and confirmation of ash blowing system valves, and adjustment and test for ash
blowing safety valves and pressure-reducing valves.
Operational test of ash blowers (coordinate with I&C personnel and manufacturers)
Simulation test of ash blower program control (coordinate with I&C personnel and
manufacturers)
8.1.9 Check and test of flame scanning cooling air system and interlock test of two fans.
8.1.10 Simulation test of periodic blowdown program control (coordinate with I&C personnel)
8.2 Non-load Stage
8.2.1 Feed water to the boilers
Water feeding mode of condensate transfer pumps (feed pumps): chemical demineralized
water--- condensate make-up water tank--- condensate transfer pump (feed pumps) ---
feedwater piping--- economizer
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Water feeding mode of motor-driven feedwater pump: Deaerator— motor-driven feedwater


pump— feedwater bypass— economizer
Feedwater Flowrate Control:
‹ Feedwater flow: 30 to 60 t/h;
‹ Feeding duration: 2 to 4 hrs
‹ The water feeding duration should be extended appropriately if the
temperature difference between water and drum wall is above 50℃;
When the water level rises up to +200mm, stop feeding water, perform drum level protection
test and ebsure the test result qualified.
8.2.2 Preparation for Ignition
Put the boiler bottom steam heating system into operation
Prior to ignition, the boiler bottom steam heating system shall be put into operation so that the
boiler water and drum wall temperature is about 100℃ and the temperature difference
between upper and lower wall is below 15℃, Slowly open the valves to supply steam to the
lower steam headers. The heating rate shall not exceed 0.5℃/min and the steam supply flow
shall be controlled properly so as to avoid excessive boiler proper vibration. Before ignition
or pressure buildup, close and isolate boiler bottom heating steam source.
Contact the relevant operators to start up electrical precipitator ash bunker and insulator
heaters.
8.2.3 Boiler Lighting-up
(1) Start up air preheater A and B.

(2) Establish ventilation ducts and furnace bottom seal.

(3) Start up induced draft fans and forced draft fan at Side A.

(4) Start up induced draft fans and forced draft fan at Side B

(5) Set furnace pressure to -100 to -200Pa

(6) Start up one flame scanning cooling fan and put another fan into standby and
interlock.
(7) Adjust the boiler draft above 30% and purge furnace;

(8) Perform fuel oil leak test;

(9) Begin to time when purging begins again. After the purging is complete, MFT shall
be reset automatically.
After confirming that the ignition conditions are met, open the main oil valves and prepare for
ignition.
After the ignition order is issued, light up the boilers.
When oil guns are put into operation, firstly start up the diagonally-arranged lower oil guns
and oil gun changeover shall be carried out periodically. Startup and changeover of oil guns
must take account of combustion conditions.
Open the drains of superheated and reheated steam piping.
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Contact operators so that HP and LP bypass systems are put into operation
Start up the steam ash blowing system of air preheaters and blow ash for air preheaters
periodically. Continuously blow ash during initial ignition stage.
8.2.4 Raising Pressure
After ignition, gradually start up oil guns according to cold-state temperature and pressure
raising curve. During initial boiler startup, an appropriately-lower temperature and pressure
raising rate may be employed.
When the drum pressure increases to 0.098 to 1.0MPa, flush drum level meters, check water
level and contact chemical operators to flush sampling lines.
When the drum pressure increases to 0.172MPa, close all vent valves at boiler top.
When the drum pressure increases to 0.4 to 0.5MPa, contact the installation contractor to
tighten bolts and contact I&C operators to flush instrument piping.
Close the drain valves according to steam temperature
When the drum pressure increases to 1.0MPa, ask chemical operators to start up dosing
system. At this time, the continuous blowdown systems may be put into operation.
Start up periodical blowdown system according to the chemical requirements.
Before the steam turbines attain stable speed, the furnace gas temperature probes shall be
inserted continuously and the furnace outlet gas temperature shall not exceed 538℃
8.2.5 Turbine Rolling
After steam temperature and pressure reach the parameters required for rolling, contact
turbine operators to allow turbine to roll. The turbine rolling parameters shall be determined
by turbine operators.
After the turbine turns, ensure that the boiler parameters meet the requirements of turbine.
When the turbine speed reaches 3000r/min, coordinate with electrical personnel to perform
electrical tests and set boiler safety valves according to actual situations.
After the electrical tests are completed, the unit shall be connected to grid and operate under
load
Furnace gas temperature probes may be withdrawn after steam is supplied boiler reheaters.
The unit shall be disconnected with grid and overspeed test shall be performed after
connection and operation with initial load for 4 to 6 hours.
After the overspeed test is completed, the turbine may be shut down while the boiler
continues to operate. The boiler safety valves shall be set.
8.3 Load Operation Stage
8.3.1 Ignition, turbine rolling, connection with grid and load operation shall be performed in the
same way so as to remove silica deposits.
8.3.2 Prepare to start up pulverizing plants according to the unit load.
8.3.3 Start up two primary fans. The following conditions shall be met before the pulverizing
system starts up:
Drum pressure>3.5MPa;

The air preheater outlet temperature shall be above 150℃.


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8.3.4 The manual desuperheating water valves shall be opened and desuperheating water shall be
available before the pulverizing plant start up.
8.3.5 Warm coal mills and start up the first coal mill according to coal mill startup procedures. For
coal mill startup procedures, refer to the Pulverizing Plant Commissioning Procedure.
8.3.6 When the coal feeding flow of the first set of pulverizing plant reaches 60 to 70 percent of
rated value, the second set of pulverizing plant may be started up according to the load (about
60MW). Contact the Ash Control Room to put the Cinder system into operation.
8.3.7 When the coal feeding flow of the second set of pulverizing plant reaches 60 to 70 percent of
rated value, the third set of pulverizing plant may be started up according to the load (about
120MW).
8.3.8 When the load reaches about 150MW, start up the second feedwater pump and allow two
pumps to operate in parallel
8.3.9 When the load reaches 40 to 60%, coordinate with I&C personnel to enable AUTO mode.
Automatic drum level control;
Automatic furnace draft control;
Automatic primary air pressure control;
Automatic coal mill air flow control
Automatic mill outlet temperature control;
Automatic desuperheating water control.
8.3.10 After all oil guns stop, continuous ash blowing for air preheaters may stop. Contact the ash
bunker operators to ensure that all electrostatic precipitators operate under electric field
control. When the load exceeds 210MW, comprehensive ash blowing may be performed for
boilers.
8.3.11 Start up the 4th coal mill and increase load.
8.3.12 When the load is about 70 to 80% and boiler attain steady combustion, perform the initial fuel
oil cut-off test.
8.3.13 Coordinate with I&C personnel to enable AUTO mode.
Automatic boiler combustion is ON;
The CCS system is ON.
8.4 Full-Load Operation Stage
Remove silica deposit when the boiler pressure is 25%, 50%, 75% and 100% rated value.
30-day trail run stage
If necessary, shut down and maintain the units after the unit trial operation under load is
completed. After then, start up the unit again, raise unit load to 315MW, and turn on the
interlock, protection and instruments as well as the automatic control system of units. The
units shall operate at full load state for at least 96hrs and operate under rated condition for 30
days to assess its reliability.
8.5 Hot Startup of Unit
8.5.1 Hot startup refers to startup which is carried out when the boiler is under pressure.
8.5.2 Prior to boiler hot startup, it is necessary to confirm that the maintenance works are complete.
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8.5.3 The procedures of boiler hot startup are basically similar to the one of cold startup.
8.5.4 Prior to ignition, all drain valves shall be closed.
8.5.5 During temperature and pressure rise, the boiler drain valves shall be controlled as follows:
(1) After ignition, fully open the drain valves of superheaters and reheaters.

(2) Open the drains upstream of the turbine MSVs and reheat steam piping drains to
warm up piping, put HP and LP bypass systems and control temperature and pressure rise
rate.
(3) After the turbine turns, close the drains of superheaters and reheaters.
8.5.6 Turn on the furnace gas temperature probes to prevent boiler tube wall from overheating.
8.5.7 After ignition, put as many oil guns as possible into operation as soon as possible provided
that the drum wall temperature difference does not exceed its limit. The purpose is to ensure
that steam parameters reach the valves required for turbine rolling as soon as possible.
8.5.8 After the turbine rotates, close the drains at turbine side according to cylinder temperature.
8.5.9 Start up pulverizing plants according to the unit load requirements. Supply desuperheating
water according to the temperature rise rate to prevent overheating.
8.6 Boiler Shutdown
8.6.1 Prior to shutdown, thoroughly check the systems and record defects.
8.6.2 Prior to shutdown, thoroughly blow ash from all heating surfaces.
8.6.3 How to Decrease Load from 315MW to 150MW.
(1) The loading-down rate shall be 1%/min.

(2) Change over main steam pressure control to MANUAL.

(3) During loading-down, the coal feeders’ speed of operating pulverizing plants shall be
reduced evenly and the primary air dampers of coal mills shall be operated evenly. When the
coal feeder speed is reduced to about 30%, one set of pulverizing plants may be stopped.
(4) When stopping coal feeders of pulverizing plants, the speed of operating coal feeders
shall be appropriately increased according to turbine and load conditions.
(5) Stop the 2nd set of pulverizing plant in the same way.

(6) When the load is reduced to 200MW (TBD), put oil guns into use to support
combustion.
(7) When the load is reduced to 150MW, one motor-driven pump may be stopped,
namely, only one pump is operating.
8.6.4 Inform the duty officer to stop electrostatic precipitator.
8.6.5 Continue to reduce load and use more oil guns to support combustion.
8.6.6 When the speed of coal feeders of rest pulverizing plants is reduced to 30%, one set of
pulverizing plant may be stopped.
8.6.7 When the load is reduced to 30%, change over automatic feedwater from three-element
control to single-element control.
8.6.8 Stop the final set of pulverizing plant and two primary air fans.
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8.6.9 Gradually stop oil guns according to loading-down situations.


8.6.10 Disconnect the generators from grids and stop turbines.
8.6.11 Boiler Shutdown
8.6.12 Stop forced draft fans and induced draft fans after purging at 30% MCR flow for 5 mins.
8.6.13 After boiler shutdown, raise drum level to the highest visual level, stop feedwater supply and
open economizer recirculation.
8.6.14 Stop air preheaters if the conditions are met.
8.6.15 Stop flame scanning cooling fans if the conditions are met.
8.6.16 Put the boilers into hot standby or drain boilers depending on actual situations, and take
measures to protect boilers against corrosion.
8.6.17 After boiler shutdown, continue to monitor exhaust gas temperature and air preheater outlet
gas temperature to prevent air preheaters from catching fire.
8.6.18 After boiler shutdown, check that all oil guns are automatically purged and then withdrawn,
and locally close manual valves of oil guns.
8.6.19 When the load and fuel supply are reduced during boiler shutdown, reduce air flow
accordingly, pay attention to water level and steam temperature and change over from AUTO
mode to MANUAL mode on a timely basis.

9. Safety Measures
9.1 Safety rules for commissioning
9.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant
safety rules, wear reasonable clothing and appropriate personal protective equipments。
9.1.2 In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning shall obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.1.4 Person from all specialties shall be on post in the whole process of test to ensure safe running
of the equipment.
9.1.5 Startup and operation of the units shall be performed under unified order and the
responsibility of each party shall be clearly determined
9.2 Personal Risk and Preventative Measures
9.2.1 Injuries might be caused by rotating equipment during commissioning or test. Therefore,
special care must be taken during work and do not touch the rotating components with tools
or your hand。
9.2.2 Commissioning personnel shall observe combustion state inside furnace properly to avoid
scald.
9.3 Equipment Risk and Preventative Measures
9.3.1 Prior to unit startup, inspection and test works shall be strengthened and defects shall be
identified and eliminated at cold state as possible. During startup, follow the temperature &
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pressure rising and loading-up curve and raise temperature, pressure and load for initial
startup as slowly as possible.
9.3.2 During boiler startup, check thermal expansion at all parts from time to time. If abnormal
expansion is found, stop raising temperature and pressure. Continue after problems are
corrected.
9.3.3 When burners have been ignited and steam has not been supplied to reheaters, ensure that the
furnace outlet gas temperature does not exceed 538℃, to protect reheaters
9.3.4 After turbines have started up, prevent sharp change in main and reheat steam temperature.
Carry-over is strictly prohibited.
9.3.5 During boiler startup and operation, pay attention to whether automatic equipments operate
correctly.
9.3.6 Pay attention to the change in air preheater outlet gas temperature and prevent reburning. If
the flue gas temperature is found to be abnormal, start up ash blowers of air preheater
immediately. At the initial stage of boiler startup, continuously blow ash till all oil guns stop.
9.3.7 Pay special attention to furnace draft change and combustion, especially when igniters and
pulverizing plants are started or stopped, in order to maintain stable combustion.
9.3.8 Ensure that the exhaust gas temperature and oxygen content in flue gas are within the
specified range and oxygen content in economizer outlet flue gas is about 4%.
9.3.9 Pay attention to furnace draft, air pressure, main steam pressure, water level, main steam
temperature, reheat steam temperature controls and other automatic controls, and correct any
problem immediately.
9.3.10 Pay attention to flame detectors, furnace flame CCTV display and observe, adjust and
maintain stable combustion
9.3.11 Check that the furnace gas probes can be put into and out of use normally.
9.3.12 During startup and operation, observe superheater and reheater wall temperature to prevent
overheating and tube burst.
9.3.13 When the load is below 50% MCR or combustion becomes unstable, put oil guns into use to
support combustion and prevent furnace explosion.
9.3.14 During boiler operation, the fuel oil systems shall be ready for operation at any time. After the
oil guns are out of use, they must be withdrawn from furnaces. Check oil guns per shift.
9.3.15 The pulverizing plants shall attain steady operation and supply coal having appropriate
fineness and coal mill outlet temperature shall be within the set range. After pulverized coal is
fed, pay attention to the change in steam temperature and pressure, load, and wall and flue
gas temperature and prevent overtemperature and excessive steam temperature variation.
When pulverized coal is initially fed, deslagging shall be strengthened (once per shift
preferred) to prevent ash accumulation inside cold ash bunkers. After the ash handling
systems attain normal operation, handle ash following the operation regulations.
9.3.16 After pulverized coal is fed, pay attention to the change in steam temperature and pressure,
load, and wall and flue gas temperature and prevent overtemperature and excessive steam
temperature variation. When pulverized coal is initially fed, deslagging shall be strengthened
(once per shift preferred) to prevent ash accumulation inside cold ash bunkers. After the ash
handling systems attain normal operation, handle ash following the operation regulations
9.3.17 During boiler startup and trial run, all interlock and protection systems shall be enabled
according to the design. Disabling of a protection shall be approved by the commissioning
leading team.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 17 of 28

9.3.18 During operation, pay close attention to bearing temperature, lube oil level and cooling water
of rotating machineries. A problem, if found, shall be reported and corrected on a timely
basis.
9.3.19 Check the operating conditions of equipments and systems from, time to time, at least twice
per shift.
9.3.20 Safeguard the commissioning areas.

10. Appendix
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 18 of 28

Appendix 1 Integral Startup Condition Checklist

Verified
No. Items Requirements Result Remarks
by
1. Mechanical system conditions
The installation and insulation are
□Yes □No
complete
The hydrostatic test and air pressure test
□Yes □No
have been completed.
(1) Boiler proper
Scaffolds, litter and foreign matters have
been removed from furnace and flue
gas& air ducts, all personnel have □Yes □No
escaped and all manholes and access
holes have been closed.
The installation and insulation are
□Yes □No
complete
Flue gas &air
(2) Commissioning of induced draft fans,
systems
forced draft fans, primary fans and air □Yes □No
preheaters are complete.
The installation and insulation are
□Yes □No
complete
The systems are complete with all
Steam and
(3) supports and hangers, and pins have □Yes □No
water system:
been removed from spring hangers.
The hydrostatic test is complete and
□Yes □No
blind plates have been removed.
The installation and insulation are
□Yes □No
complete
Fuel oil system Individual commissioning of all oil
(4) □Yes □No
pumps has been successfully completed
The oil piping has been successfully
□Yes □No
purged
The installation and insulation are
□Yes □No
complete
Static commissioning of coal mills and
Pulverizing □Yes □No
(5) feeders are complete.
plant
Individual commissioning of coal mills,
feeder and auxiliary facilities are □Yes □No
complete.
Installation, individual commissioning
of .all equipments and acceptance check □Yes □No
are complete
Coal handling
(6) Ready to transfer coal to coal bunker at
system □Yes □No
any time
The raw coal bunkers have been
□Yes □No
thoroughly cleaned.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 19 of 28

The installation and insulation are


□Yes □No
complete
Electrostatic Voltage increase and rapping test are
□Yes □No
(7) precipitator complete
system
All electrostatic precipitators and
economizer ash bunkers are thoroughly □Yes □No
cleaned
The installation and insulation are
Ash and cinder □Yes □No
complete
(8) handling
system Individual commissioning of auxiliary
□Yes □No
facilities are complete.
Flame scanning The installation and individual
(9) cooling air commissioning of flame scanning □Yes □No
system cooling fans are complete
The installation and insulation are
□Yes □No
complete

Ash blowimg The piping has been purged with steam □Yes □No
(10)
Systems Static commissioning of all ash blowers
□Yes □No
has been successfully completed.
Ready for operation □Yes □No
Auxiliary systems, such as the dosing,
sampling, periodic and continuous
Auxiliary
(11) blowdown, drain, vent, back flushing □Yes □No
system
and inert gas flushing systems, have
been installed and insulated.
Boiler bottom
The systems have been installed and
(12) steam heating □Yes □No
insulated and are ready for operation.
system
Boiler All expansion indicators have been
(13) expansion installed as per the design and reset to □Yes □No
system; zero position.
Adequate fire fighting material are
Fire protection available and fire water systems have
(14) □Yes □No
system been installed and commissioned and
ready for use
Industrial water The systems have been installed and
(15) □Yes □No
system; commissioned and ready for use
2 Electric, instrument and control condition
Motor-driven
The static commissioning is complete
and pneumatic
(1) and valves and dampers can move freely □Yes □No
valves and
in correct direction.
dampers
Static commissioning are complete and
(2) Alarm systems □Yes □No
indication is correct
Emergency The pushbuttons are functional and
(3) □Yes □No
pushbutton for wired correctly.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 20 of 28

rotating
machinery
Commissioning is complete, startup and
Auxiliaries
(4) stop logic are correct and equipments □Yes □No
PLC system
can operate normally
The static commissioning is complete,
(5) FSSS □Yes □No
logic is correct and movement is reliable
Static commissioning is complete and
the name and indication of all data □Yes □No
Data points are correct.
acquisition and
(6) Static commissioning of the industrial
supervisory
control system CCTV systems and flame detector
□Yes □No
systems has been completed and they
are ready for operation at any time.
Automatic
Static commissioning is complete and
weighing
(7) the systems are able to measure and □Yes □No
system of coal
indicate coal weight accurately.
feeders
Furnace gas Static commissioning and setting are
(8) temperature complete and the probes can move □Yes □No
probe freely.
Program
The static commissioning has been
control of ash
successfully completed and simulation
(9) blowing and □Yes □No
tests indicate that the relations are
periodic
correct and movement is reliable.
blowdown
Combined
interlock test
covering the The simulation test is complete, logic is
(10) □Yes □No
turbine, boilers correct and movement is reliable
and electrical
systems
3 Civil works
Clear
Road
(1) Adequate normal and emergency □Yes □No
Lighting
lighting facilities is available
(2) Fire apparatus Adequate □Yes □No
Communicatio Easy to use, adequate fire fighting
(3) □Yes □No
n equipments apparatus are available
4 Commissioning items which should be completed
Boiler proper Has been pickled
Temporary Has been washed with alkali
(1) □Yes □No
systems of The normal system configuration has
boiler front-end been resumed
Dampers of
(2) flue gas and air Commissioning is complete □Yes □No
systems as well
PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 21 of 28

steam and
water valves
Cold-state The leveling and air flow calibration are
(3) □Yes □No
ventilation complete
Boiler piping
blowing. Fulfilled
(4) □Yes □No
Temporary Have been removed
system
Auxiliary
(5) sequential Have been checked and tested □Yes □No
control
(6) FSSS Have been checked and tested □Yes □No
Emergency
pushbutton for
(7) Have been checked and tested □Yes □No
rotating
machinery
(8) Alarm signal Have been checked and tested □Yes □No
5 Other conditions
Chemical water In good order and ready to supply
(1) □Yes □No
system demineralized water as per the design
Compressed air In good order and ready to supply
(2) □Yes □No
system compressed air as per the design
Station service In good order and ready to supply power
(3) □Yes □No
system as required
Lighting and
(4) communication In good order and ready to communicate □Yes □No
system;
Central A/C Have been commissioned and read for
(5) □Yes □No
system operation at any time

Commissioning Contractor: Date: Operation Contractor: Date:

Contractor: Date: Dongfang Electric: Date:


PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 22 of 28

Appendix 2 Boiler Commissioning Parameter Record


Time Condition
Description Unit Data Description Unit Data
Unit load MW A APH outlet primary air temp ℃
Main steam flow T/h B APH outlet primary air temp ℃
Main steam pressure MPa Furnace draft PA
Main steam temp ℃ Oxygen concentration at furnace outlet %
Drum pressure MPa Oxygen content at air preheater outlet %
Drum level mm Flue gas temperature at air preheater A inlet ℃
Feed water flow T/h Flue gas temperature at air preheater A outlet ℃
Feed water press MPa Flue gas temperature at air preheater B inlet ℃
Temp. of feed water ℃ Flue gas temperature at air preheater B outlet ℃
st
1 stage desuperheating water flow T/h Outlet flue gas temp. of furnace ℃
2nd stage desuperheating water flow T/h Flue gas temperature at economizer inlet ℃
3rd stage desuperheating water flow T/h Temp. of flue gas ℃
A FD fan current A Reheat steam flow T/h
B FD fan current A Reheat steam inlet pressure:
Opening of stationary blade of
% Reheat steam outlet pressure: MPa
induced draft fan A
Opening of stationary blade of
% Reheat steam inlet temperature ℃
induced draft fan B
Air pressure at induced draft fan A
KPa Reheat steam outlet temperature ℃
inlet
Air pressure at induced draft fan B
KPa Reheater emergency water spray flow T/h
inlet
A FD fan current A Reheater micro water spray flow T/h
B FD fan current A Ceiling superheater wall temperature ℃
A FD fan dynamic blade opening % Wall enclosure superheater wall temperature ℃
B FD fan dynamic blade opening % Low-temperature superheater wall temperature ℃
A FD fan outlet air press KPa Platen superheater wall temperature ℃
B FD fan outlet air press KPa Rear platen superheater wall temperature ℃
A APH outlet secondary air temp ℃ High-temperature superheater wall temperature ℃
B APH outlet secondary air temp ℃ Platen reheater wall temperature ℃
Secondary air tank pressure at Side
KPa High-temperature reheater wall temperature ℃
A
Secondary air tank pressure at Side
KPa Burner angle of swing %
B
Primary air fan A current A B primary fan current A
IGV opening of primary air fan A % IGV opening of primary air fan B %
Air pressure at primary air fan A
KPa Air pressure at primary air fan B outlet KPa
outlet

Commissioning Contractor: Date: Operation Contractor: Date:

Contractor: Date: Dongfang Electric: Date:


PLTU 1 Jatim-Pacitan(2×315MW) Project
Commissioning Procedure of Boiler Integral Start-up REV A
Procedure
SCCTI-TS-GL-CS-002-2009A Page 23 of 28

Appendix 3 Commissioning Parameter Record for Pulverizing Plants

Time Condition
Description Unit A B C D E
Coal mill current A
Coal feeding flow t/h
Primary air flow entering mill t/h
Mill inlet pressure KPa
Mill outlet pressure KPa
Differential pressure across coal mill KPa
Differential pressure across mill grinding disc KPa
Temperature of coal pulverizer motor bearing ℃
Temperature of mill motor stator winding ℃
Air temperature at coal mill inlet ℃
Outlet temperature of coal pulverizer is >55℃ ℃
Differential pressure across mill grinding roll KPa

Commissioning Company: `Date: `Operation Company: `Date:

Construction Contractor: `Date: `DEC: `Date:


PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Boiler Integral Start-up REV A


Commissioning
Procedure SCCTI-TS-GL-CS-002-2009A Page 24 of 28

Appendix 4 Record for Boiler MFT (OFT) and Integral Interlock Test

No. Test item Fixed value Results Remarks


1. Furnace purging permissive
(1) No MFT trip conditions
(2) No flame is detected by a flame detector
(3) Any forced draft fan operating
(4) Any induced draft fan is running
(5) The furnace pressure is normal (from the MCS)
(6) No emergency boiler stop pushbutton pressed
(7) Fuel oil return mains shutoff valve closed
(8) Fuel oil mains quick-closing valve closed
(9) All the oil valves closed
(10) All coal mill stopped
(11) Al primary air fans stopped
(12) All coal feeders stopped
(13) Both air preheater are operating
(14) Swinging burners at horizontal position
(15) Air flow entering furnace (from the MCS) higher than 30% BMCR
(16) Air flow entering furnace (from the MCS) lower than 40% BMCR
(17) All secondary air dampers are at PURGING position
(18) Furnace pressure normal
(19) Flame detector cooling air pressure normal
(20) Normal drum level (two-out –of three)
2. Check MFT condition
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Procedure SCCTI-TS-GL-CS-002-2009A Page 25 of 28

(1) Control power failure: Power supply to the FSSS cabinet fail
(2) Two forced draft fans stop
(3) Two induced draft fans stop
(4) Manual MFT
(5) Drum level above +250mm (two-out of-three, at least 2s)
(6) Drum level below -250mm (two-out of-three, at least 2s)
(7) High furnace draft (2 out of 3), set value +1960Pa without time delay
(8) Low furnace draft (2 out of 3), set value -1960Pa without time delay
(9) Air flow entering furnace <30% for at least 60s
a. Load >40%, steam turbine tripped
(10) When the load is below 40%, the turbine is tripped after 2s and the bypass is invalid (the HP bypass valve
is closed or all of LP bypass is closed)
(11) Coal mills at any layer is running, all primary air fans stop and no oil layer is operating
(12) All air preheaters stop, 5s time delay
Total flame loss (3s pulse). When 3/4 oil flame detectors do not detect flame and 3/4 coal flame detectors
do not detect flame, it is considered that no flame is detected inside furnaces. When no flame is detected
and burner operation is recorded, all flame loss is generated. That is to say, all flame loss is not assumed
for a boiler not running.
(13) All furnace flameout (all flame loss)
¾ When only fuel oil is fired, total furnace flameout (3 out of 4 for each layer)
¾ When only coal is fired, total furnace flameout (3 out of 4 for each layer)
¾ When both oil and coal are fired, total furnace flameout
All fuel loss (5 s pulse): when all oil valves are closed or quick-closing valves on oil mains are closed, and
all coal feeders stop or all coal mills stop AND “Burner Operation” signal.
(14) All fuel loss
¾ When only oil is fired, angle oil valves are fully closed or quick-closing oil valves are closed
¾ When only coal is fired, fuel operation is recorded and all coal mills stop
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Boiler Integral Start-up REV A


Commissioning
Procedure SCCTI-TS-GL-CS-002-2009A Page 26 of 28

¾ When both oil and coal are fired, angle oil valves are fully closed or quick-closing oil valves are
closed AND “ Fuel Operation” and all coal mill stop.
(15) Low flame scanning cooling air pressure, <5.5kPa (10s time delay, 2 out of 3)
(16) All flame scanning cooling fans stop
(17) All feedwater pumps stop
Re-purge request (a short pulse is issued if no angle oil valve is opened within 60 min after purging is
(18)
complete)
(19) Generator transformer protection is triggered
3. Equipment interlocked with MFT
(1) audible and visual alarm are issued and furnace purging request is issued
Trip all oil burners, close all oil valves, trip and withdraw oil guns, prohibit and withdraw ignition guns,
(2)
disable oil gun purging and close all purge valves
(3) Close oil supply fast valve of oil manifold
(4) Close motor-driven valves on oil return mains
(5) Trip all coal pulverizers
(6) Trip all coal feeders
(7) Close all mill outlet air dampers;
(8) Close cold and hot air quick-closing valves as well as cold and hot air regulating valves of all coal mills.
(9) Trip all primary fans (including sealing air fans)
(10) Send MFT signal to the CCS, SCS and ETS systems etc.
Change over two forced draft fans from AUTO to MANUAL, automatically reduce the opening to startup
(11)
purging position (when the total air flow at purging position is above 30%)
Change over two induced draft fans from AUTO to MANUAL, move the IGV to purging position to
(12)
maintain a normal furnace pressure
¾ Furnace FSSS natural draft (when stopping of induced and forced draft fans causes MFT, the
(13) stationary and moving blade of fans will be fully opened and locked for 15min), all air dampers of
burners will be fully opened after 1min and control will be changed over from AUTO to MANUAL.
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Boiler Integral Start-up REV A


Commissioning
Procedure SCCTI-TS-GL-CS-002-2009A Page 27 of 28

¾ Adjust air flow to the minimum purging flow (when the total flow at purging position is above 30%,
the moving blade of forced draft fans will reach the purging position automatically, stationary blades
of induced draft fans enter protection mode to maintain furnace pressure), all burner air dampers are
fully opened and the control will be changed over from AUTO to MANUAL
¾ Maintain current air flow, all burner air dampers remain positions and fully opened after 5min, the
control will be changed from AUTO to MANUAL and moving blades will be forced for 5min (when
the total air flow is below 30%, the moving blades of blowers remain position and stationary blades
of induced draft fans are under protection mode to automatically maintain furnace pressure)
(14) Trip MFT relay (fail-trip)
Main and auxiliary desuperheating water valves of superheater systems are closed, all regulating valves
(15)
are closed to zero position and the control is changed over from AUTO to MANUAL.
Main and auxiliary desuperheating water valves of reheater systems are closed, all regulating valves are
(16)
closed to zero position and the control is changed over from AUTO to MANUAL.
Trip ash blowing systems: close the main motor-driven valve, and operating ash blowers need be out of
(17)
service.
(18) Send MFT signal to the CCS, SCS and ETS systems
(19) Steam turbine tripped
(20) Generator transformer protection tripped
(21) The swinging mechanism of burners moving to horizontal position automatically
(22) Electrostatic precipitators tripped
4. Logic check for FSSS hard-wired control circuit
(1) All primary air fans tripped
(2) All mills tripped
(3) All coal feeders tripped
(4) Fuel oil return electric valves closed
(5) Quick-closing fuel oil supply valves closed
(6) All angle oil valves of oil guns fully closed
PLTU 1 Jatim-Pacitan(2×315MW) Project

Procedure of Boiler Integral Start-up REV A


Commissioning
Procedure SCCTI-TS-GL-CS-002-2009A Page 28 of 28

(7) The main electric desuperheating water valves of superheaters close


(8) The main electric desuperheating water valves of reheaters close
(9) Electrostatic precipitators tripped
(10) Ash blowing systems tripped
(11) ETS loss
5. Combined interlock test covering the turbine, boilers and electrical systems
(1) When boiler MFT occurs, the ST and generator oil circuit-breakers shall be tripped
When the ST is tripped and load is above 40%, the boiler MFT shall be triggered and generator oil
(2)
circuit-breakers shall be tripped
When the generator-transformers are tripped, the ST shall be tripped. When the ST is tripped and the load
(3)
is above 40%, the boiler shall be tripped.
6. MFT resetting condition (AND)
(1) Furnace purging finished
(2) No MFT trip conditions

Commissioning Contractor: Date: Operation Contractor: Date:

Contractor: Date: Dongfang Electric: Date:


PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HH-001

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Procedure of Fuel Cutoff and Stabilizing
Review Design
Burning
Date Scale N/A DWG No. SCCTI-TS-GL-CS-003-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
调试程序
Procedure of Fuel Cutoff and Stabilizing Burning REV A
Commissioning
Procedure SCCTI-TS-GL-CS-003-2009A Page 2 of 15

Table of Contents

1. PURPOSE ............................................................................................................................................ 3

2. SCOPE ................................................................................................................................................. 3

3. PREPARATION BASIS............................................................................................................... 3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT ............................................................... 3

5. TOOLS AND INSTRUMENT FOR COMMISSIONING................................................................... 5

6. PREREQUISITE FOR COMMISSIONING ....................................................................................... 5

7. MEASURES FOR COMMISSIONING ORGANIZATION ............................................................... 6

8. COMMISSIONING PROCEDURE .................................................................................................... 7

9. SAFETY MEASURES ........................................................................................................................ 9

9.1 Safety rules for commissioning .......................................................................... 9


9.2 Personal Risk and Preventative Measures.......................................................... 9
9.3 9.3 Equipment Risk and Preventative Measures ................................................ 9

10. APPENDIX................................................................................................................................ 10

Appendix 1 Commissioning Condition Checklist.......................................................... 11


Appendix 2 Format for Trial Run Record ...................................................................... 12
Appendix 3 Test Coal Quality Record............................................................................ 14
Appendix 4 Pulverized Coal Fineness Record ............................................................... 15
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Procedure of Fuel Cutoff and Stabilizing Burning REV A
Commissioning
Procedure SCCTI-TS-GL-CS-003-2009A Page 3 of 15

1. Purpose
Stable combustion and safe fuel oil cut-off reached in the process of commissioning for boiler
start-up with load can save fuel oil and increase economic operation of units.

2. Scope
This procedure is applicable to the commissioning of low load stable combustion after boiler
fuel oil cut-off, including check and verification of boiler protection, combustion setting
before fuel oil cut-off, fuel oil cut-off test and combustion setting after fuel oil cut-off.

3. Preparation Basis
3.1 DRGs of flue-gas and air system and pulverized coal system;
3.2 Manual of boiler performance and structure;
3.3 Manual of combustion equipment;
3.4 Manual of coal mill.

4. Brief Description of System and Equipment


4.1 Two sets of natural circulation drum boilers with subcritical parameter and four corner
tangential firing are provided in this project. It has single furnace with half open arrangement
of II Type, brown coal fired, single reheating, balanced ventilation, solid slag removing, all
steel structure and with metal rain shed on furnace top. All these three boilers are designed
and manufactured by Dongfang Boiler Group Co,. Ltd. Boiler model: DG1025/17.4-II13. The
firing mode in furnace is a positive, direct blowing, four-corner tangential firing with swing
of burner nozzles. For the steam temperature of super heated steam, the water spray
temperature reducer with I,II and III steps is provided for the adjustment of temperature and
the arrangement of three steps and five points is provided. The swinging of burner nozzle is
used as the main way to adjust the steam temperature of the reheated steam, reducing
temperature with water spray as auxiliary and spray temperature reducers are provided as
well。

4.2 Main Parameters of Boiler (Design type of coal)

Item Unit BMCR Condition ECR condition

Work pressure of boiler drum MPa 18.77 18.58


Flow of superheated steam t/h 1025 976.2
Outlet pressure of superheated steam MPa 17.4 17.32
Outlet temperature of super heated
℃ 541 541
steam
Flow of reheated steam t/h 839.4 802
Inlet/outlet temperature of reheated
MPa 3.76/3.58 3.59/3.41
steam
PLTU 1 Jatim-Pacitan(2×315MW) Project
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Procedure of Fuel Cutoff and Stabilizing Burning REV A
Commissioning
Procedure SCCTI-TS-GL-CS-003-2009A Page 4 of 15

Inlet/outlet pressure of reheated


℃ 329/541 324/541
steam
Temp. of feed water ℃ 281 278
Temp. of flue gas ℃ 131 131
Outlet flue gas temp. of furnace ℃ 985 994
Inlet air temp. of air PH ℃ 30 30
Outlet air temp. of air PH ℃ 359/351 359/351
Calculated consumption of boiler fuel t/h 161.58 154.23
Calculated efficiency of boiler % 93.26 93.71

4.3 Swing burners are adopted as burners which are arranged in four corners and double
tangential firing is formed in the furnace and the presumed tangential are ф548mm and
ф1032mm respectively. The horizontal bias burning technique in the design of pulverized
coal nozzles is used to strengthen the stability of combustion in boiler when running with low
load.
Feature Data of Burner (design coal type/BMCR load)

Air-to coal Air Flowrate Air Temperature Resistance


No. Item
Ratio (%) (m/s) (℃) (Pa)
1 Primary air 28 65 1900
2 Secondary air 45 346 1000
3 Thrice air
3 Surrounding air 35 346 ——
Furnace air
4
leakage

4.4 Features of Fuel as below:

Design coal Verified coal


No. Item Symbol Unit
type type
1 Carbon (as-received basis) Car % 47.65
2 Hydrogen (as-received basis) Har % 3.36
3 Oxygen (as-received basis) Oar % 13
4 Nitrogen (as-received basis) Nar % 0.77
5 Total sulphur (as-received
Sar % 0.23
basis)
6 Ash content (as-received
Aar % 5
basis)
7 Water content (as received
Mar % 30
basis)
8 Water content as air dried
Mad % 20
basis
9 Volatile matter (dry ash-free Vdaf % 54
PLTU 1 Jatim-Pacitan(2×315MW) Project
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basis)
10 Net calorific value Qnet.ar Kcal/kg 4200
11 Hardgrove grindability
HGI 45
coefficient
12 Ash deformation temperature DT ℃ 1150
13 Ash softening temperature ST ℃ 1200
14 Ash fusion temperature FT ℃ 1300

4.5 Characteristics of Fuel Oil

Items Unit Light Diesel Oil


Maximum ash content %
Max. sulfur content %
Max. water content (vol%) %
Residue (wt %) %
High heat value kJ/kg
Density (15℃) kg/m3 ≥847
Kinematic viscosity (100℃) Cst ≥1.0
Pour point ℃
Flash point (closed cup) ℃ ≥50
Relevant Indian standards

Details will be given after providing the instruction.

5. Tools and Instrument for Commissioning


5.1 Walkie talkie;

5.2 Vibration measurement instrument;


5.3 Infrared thermodetector.

6. Prerequisite for Commissioning


Before formally beginning commissioning job, commissioning persons should conduct
comprehensive checks on conditions that should be available for commissioning of this
system according to contents listed in Attachment 1 (Commissioning Condition Checklist)
and make well the records.
6.1 Each function of FSSS must be tested prior to start-up of boiler to ensure its action is correct
and reliable. All of its functions will be put into service step wise in the process of the trial
run.
6.2 The main protection of boiler must be checked and verified again before fuel oil cut-off of
boiler. For individual protection which is released because of fault or can not be put into
service, approval by the command group of trial run is required for the execution and for the
important one, and approval by the leadership group of trial run is required for important
items.
6.3 The combustion in the furnace shall be observed and checked again prior to fuel oil cut-off of
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boiler to ensure that the firing is stable, flame is clear, there is no obvious coking or other
abnormal situation.
6.4 The adjustment test for pulverization plant and firing in boiler has been completed and the
plant runs normally before fuel oil cut-off test.
6.5 The hot-state adjustment of pulverizing plant is finished and the fineness of coal powder is up
to the design requirement.
6.6 Confirm that coal quality conform to design requirements prior to fuel oil cut-off. During the
test, the significant change in coal quality is not allowable and coal quality shall remain in the
normal range.
6.7 Prior to the test, the boilers have operated for at least successive 12 hrs, the boilers have attain
steady operation for at least 2 hrs under the test load, the units have attained steady operation,
main parameters are normal and main and auxiliary equipments operate properly.
6.8 Before fuel oil cut-off, the related automation at boiler side shall be tried to put into service
(for instance, feed water, desuperheating water auto, auto of ID, FD and primary fans and
auto of main steam pressure).
6.9 A complete ash steam purging for boiler proper shall be conducted before fuel oil cut-off.
6.10 The possible accidents, such as fire out, water cut-off, turbine tripping and no auxiliary power
supply, shall be considered properly before fuel oil cut-off.
6.11 HP heater shall be put into service in the test to ensure that the pressure prior to TG stable.
6.12 The measure points of temperature on up and down wall of boiler drum, temperature of SH
tube wall and temperature of RH tube wall shall be checked for correctness of reading before
the test.
6.13 The fire protection of boilers is put into normal operation and flame scanning signals are
sensitive and reliable.
6.14 The hot air recirculation is put into operation to increase air preheater inlet air temperature
and prevent low-temperature corrosion of air-preheaters.
6.15 The outlet damper of coal mill separator has been adjusted properly as per requirement of
coal powder fineness before the test.
6.16 The adjustment of burners is free and its action is reliable.
6.17 Test instruments are available.

7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
Contractors shall cooperate closely with each other according to their respective work
responsibilities so as to guarantee safe and effective implementation of commissioning. The
division of works is as follows:
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;
◆ Preparation of commissioning plan;
◆ Preparation of instruments and equipment required for commissioning;
◆ Hold technical clarification meeting for commissioning;
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◆ Organize the commissioning work to be carried out by various parties;


◆ Give instructions to operators in the operation;
◆ Prepare commissioning report.
7.2 Responsibilities of Installation Contractor
◆ Be responsible for individual commissioning of equipment and provide relevant record
and certificate of commissioning;
◆ Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;
◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;


◆ Be responsible for temporary coordination of local control and instruments and
connection terminals.
7.3 Responsibilities of Equipment Manufacturer
◆ Representative of manufacturer, if present on the site offering service, shall provide
technical assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator
◆ Prepare tools to be involved in operation;
◆ Prepare operation log and forms;
◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;
◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;
◆ Be responsible for dealing with the accidents occurred in commissioning.
7.5 Responsibilities of Dongfang Electric
◆ Be responsible for supervision and control over commissioning work;
◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;
◆ Organize analysis and settlement of major technical issues in commissioning.
7.6 Responsibilities of Owner
◆ Supervise the execution of commissioning procedures;
◆ Witness the commissioning work;
◆ Accept the results of commissioning.
8. Commissioning Procedure
8.1 Time schedule and method for tests
The test can be conducted at night when the unit peak load is controlled by the power grid as
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per arrangement in trial run plan. The test schedule will be submitted to dispatch center for
approval before it is executed. It is requested, under permit able condition, that the operation
of the mill corresponded to the lowest layer powder nozzle shall be kept by all means to
maintain the lower flame center and firing stably in the purpose of ensuring the temperature
of SH metal wall in the normal range and proper main and reheated steam temperature.
8.2 Test Procedures
8.2.1 During firing adjustment, the output of upper layer burners shall be reduced gradually with
the decrease of electric load and the coal reduction shall be done slowly, firstly fast and then
slow. Shut down the fourth pulverizing plant and close corresponding secondary air damper
(or the lowest opening to cool the burner) when the load is reduced to 80%. If the burning is
proper at this moment and coal flame scanned stable, the output of the third pulverizing plant
can be reduced continuously. If the signal of flame scanning becomes weak in large extent or
the fluctuation of negative pressure in the furnace increases, it shows that the firing stability
in the furnace is affected. The load reduction shall be stopped when there is no improvement
after adjustment. The load reduction can be continued when firing condition has been
improved after corresponding firing adjustment. In addition, the outlet flue gas temperature of
furnace shall be monitored for maintaining at relatively high level.
8.2.2 Shut down the third pulverizing plant when the load reduced to approximately 60% with the
same method above. Close the corresponding secondary air damper after shutting down the
mill.
8.2.3 Continue to reduce load and when the load is reduced to less than 60%, keep the first and
second pulverizing plant working and the output will be reduced gradually with the change of
load. First reduce the fuel volume of upper layer and then the lower layer. While reducing the
fuel, the primary air of the pulverizing plant shall be adjusted properly to maintain proper
speed of primary air, coal powder density and higher outlet temperature of coal mill. At the
same time, the secondary air will be reduced properly to maintain rational content of oxygen
and the air and coal ratio curve of coal mill shall be noted and the primary air volume shall be
adjusted to maintain proper density of primary air and powder at spout of burners.
8.2.4 Stop load reduction when the load is reduced to 50% and there is obvious weakening of
signal from flame scanner of A and B layers. The test can start when, from observation
through local flame opening, flame in the furnace is stable and bright, firing point of flame
nozzle is proper and the temperature at furnace outlet is not reducing any more and is
basically stable.
8.2.5 Confirm operating condition after the boilers have attained steady operation for 1 hr.
8.2.6 After verification of work condition and firing stable, maintain running stably for 2 hrs at this
load until the test is completed. All types of boiler protection shall be put into service in the
process of test and for stable firing and facilitating the control; the primary air volume control
of mill can be switched over to manual while all others will be put into service automatically.
8.2.7 The primary and secondary air volume of all burners will be controlled by auto adjustment.
The auto can be released, if necessary, and conduct the adjustment manually.
8.2.8 During the test, the participant of test shall strengthen local firing observation and the
operator shall strengthen monitoring parameters of flame scanning signal, negative pressure
in furnace, volume of primary air, volume of secondary air, oxygen content, flue gas
temperature, etc. If the fluctuations are great, the fuel reduction can be suspended and the test
can be continued after the firing is adjusted to stable.
8.2.9 The speed of coal and load reduction in the test depends mainly on the change of firing
intensity and stability and the maintenance of proper primary air volume, secondary air
volume and oxygen content shall also be noted.
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8.2.10 Record and measurement of data in test


Raw coal sampling and analysis shall be done every 1hour during the test.

9. Safety Measures
9.1 Safety rules for commissioning
9.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant
safety rules, wear reasonable clothing and appropriate personal protective equipments.
9.1.2 In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Then investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning shall obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.1.4 Person from all specialties shall be on post in the whole process of test to ensure safe running
of the equipment.
9.1.5 The process of fuel oil cut-off and load reduction shall be commanded on a uniform basis and
operation shall be done carefully.
9.2 Personal Risk and Preventative Measures
9.2.1 Flame observers shall communicate frequently with CCR operators. Flame observers shall
use correct methods to avoid burns.
9.3 9.3 Equipment Risk and Preventative Measures
9.3.1 Suspend all other tests and important operation in the process of the test. If there is an
important operation, suspend the test firstly.
9.3.2 In case unstable firing is observed in the process of fuel oil cut-off and load reduction, fuel oil
shall be filled to assist firing. It shall be verified that the firing in the furnace is not
extinguished before filling the fuel oil.
9.3.3 When the bad firing of individual burner is observed during the test, suspend load reduction
and adjust firing. The load reduction and the test can only be continued until the firing is
stable.
9.3.4 If it is found that the fluctuation of negative pressure in the furnace is greater, parameters of
load, steam temperature and steam pressure are abnormal and flame cannot be seen on flame
TV in the process of fuel oil cut-off and load reduction, firing extinguished can be determined.
If MFT doesn't work at this moment, immediately operate MFT manually.
9.3.5 The operation person shall operate smoothly and slowly when reducing load in the process of
the test.
9.3.6 Necessary pre-setting of important parameters, such as steam temperature, etc. shall be done
properly when the coal mill is suspended.
9.3.7 When reducing primary air pressure and secondary air volume, reduce coal feed first and then
reduce air volume. The operation shall be slow to avoid air amount fluctuating in large extent,
resulting in disturbance of steam temperature, load, etc.
9.3.8 Boiler ash blowing or other work, which affecting firing in the boiler, shall be prohibited
during the test.
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9.3.9 Gradually reduce boiler load with the margin of 3%~10% of rated load in the process of test
and maintain for 15 to 30min under each step of load until the lowest load of stable firing is
reached.
10. Appendix
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Appendix 1 Commissioning Condition Checklist


Remar
No. Items Requirements Result Verified by
ks
1 Function test of FSSS system Action correct and reliable □Yes □No
Inspection and verification
2 of main protection
Reliable □Yes □No

Inspection of firing in
3 furnace
firing stable and flame clear □Yes □No

Pulverizing plant adjustment


4 and combustion adjustment Completed □Yes □No
and test
Pulverizing plant and Operate normally, acceptable
5 fineness of pulverized coal fineness
□Yes □No

6 Coal quality Stable and meet requirements □Yes □No


Have operated continuously
Unit operation prior to the for at least 12 hrs
7 test
□Yes □No
Have operated for at least 2
hrs under the test load
Automatic control at boiler
8 side
Try best to put into service □Yes □No

Completed before fuel oil


9 Ash steam blowing
cut-off
□Yes □No

10 Presume of accident Completed □Yes □No


Commissioning is finished,
11 Cooling water system
can be put into operation
□Yes □No

12 HP heater system Put into operation □Yes □No


Reading correct and up to
13 Temperature measure point
standard
□Yes □No

Fire extinguish protection Protection put into service


14 and flame scanning signal and signal reliable
□Yes □No

Adjustment free and action


15 Burners
reliable
□Yes □No

Outlet damper for coal mill Adjustment as per coal


16 separator powder fineness completed
□Yes □No

17 Testing Instruments Prepared □Yes □No

Commissioning Contractor: Date: Operation Contractor: Date:

Contractor: Date: Dongfang Electric: Date:

Owner Date:
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Appendix 2 Format for Trial Run Record

Time Condition
Name Unit Data Name Unit Data
Unit load MW Furnace negative pressure Pa
Oxygen concentration at furnace
Main steam flow T/H %
outlet
Oxygen content at air preheater
Main steam pressure MPa %
outlet
Flue gas temperature at air
Main steam temp. ℃ ℃
preheater A inlet
Flue gas pressure at air preheater
Drum pressure MPa ℃
A outlet
Flue gas temperature at air
Drum level mm ℃
preheater B inlet
Flue gas temperature at air
Feed water flow T/H ℃
preheater B outlet
Feed water pressure MPa Outlet flue gas temp. of furnace ℃
Flue gas temperature at
Temp. of feed water ℃ ℃
economizer inlet
First step temp. reduction water
T/h Temp. of flue gas ` ℃
flow, A Side
First step temp. reduction water
T/h Flow of reheated steam T/h
flow, B Side
Second step temp. reduction
T/h Reheat steam inlet pressure MPa
water flow, A Side
Second step temp. reduction
T/h Reheat steam outlet pressure MPa
water flow, B Side
Reheat steam inlet and outlet
A/B IDF current A ℃
temperature
Reheat desuperheating water flow
A/B IDF static blade opening % T/H
at Side A/B
Steam temperature upstream of
A IDF inlet air pressure KPa ℃
Stage 1 desuperheating water
Steam temperature downstream
B IDF inlet air press KPa ℃
of Stage 1 desuperheating water
Steam temperature upstream of
A FD fan current A ℃
Stage 2 desuperheating water
Low-temperature superheater wall
B FD fan current A ℃
temperature
A FD fan dynamic blade Platen superheater wall
% ℃
opening temperature
B FD fan dynamic blade High-temperature superheater
% ℃
opening wall temperature
Low-temperature reheater wall
A FD fan outlet air pressure KPa ℃
temperature
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High-temperature reheater wall


B FD fan outlet air pressure KPa ℃
temperature
A APH outlet secondary air
℃ A Primary air fan current A
temp.
B APH outlet secondary air
℃ B primary air fan current A
temp.
A primary air fan guide blade Air pressure at primary air fan A
% KPa
opening outlet
B Secondary air fan guide blade Air pressure at primary air fan B
% KPa
opening outlet
A APH outlet primary air temp. ℃ B APH outlet primary air temp ℃

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
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Appendix 3 Test Coal Quality Record

Coal Quality Record


Testing time Recorded by
Test condition Unit 1 2 3 4 5 6
Load MW
Total moisture M %
Ash content Ag %
Fixed carbon Cg %
Volatile matter Vg %
Q Dw kcal.
combustible content in fly %
content
Combustible content in slag %
Fineness of pulverized coal %

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
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Appendix 4 Pulverized Coal Fineness Record

Pulverized Coal Fineness


Testing time Recorded by
Remark
Test condition Unit Mill A Mill B Mill C Mill D Mill E
s
Load MW
Primary air flow at mill inlet T/h
Primary air temperature at mill

inlet
Coal feeding flow T/h
Outlet temperature of coal

pulverizer separator
Differential pressure through
KPa
mill separator
Coal mill current A
Fineness of pulverized coal %

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) DWG No.
0702-00-M-01-HH-002

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
SiChuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW) DESIGN STAGE
Commissioning & Test Institute Project
Approval Check
Review Design Procedure of Burning Commissioning
Date Scale N/A DWG No. SCCTI-TS-GL-CS-004-2009A REV A
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SCCTI-TS-GL-CS-004-2009A Page 2 of 17

Table of Contents

1. PURPOSE ..........................................................................................................................................................3

2. SCOPE ...............................................................................................................................................................3

3. PREPARATION BASIS.....................................................................................................................................3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .............................................................................3

5. TOOLS AND INSTRUMENT FOR COMMISSIONING.................................................................................4

6. PREREQUISITE FOR COMMISSIONING......................................................................................................4

7. MEASURES FOR COMMISSIONING ORGANIZATION .............................................................................6

8. COMMISSIONING PROCEDURE...................................................................................................................7

9. SAFETY MEASURES.......................................................................................................................................8

9.1 Safety rules for commissioning.......................................................................................8


9.2 Personal Risk and Preventative Measures.......................................................................9
9.3 Equipment Risk and Preventative Measures...................................................................9

10. APPENDIX ................................................................................................................................................9

Appendix 1 Commissioning Condition Checklist.......................................................................10


Appendix 2 Boiler Combustion Parameter Adjustment Record .................................................13
Appendix 3 Opening Record for All Small Secondary Air Dampers .........................................14
Appendix 4 Furnace Temperature Record...................................................................................15
Appendix 5 Record of Oxygen Content in Flue Gas ..................................................................16
Appendix 6 Coal Quality Record ................................................................................................16
Appendix 7 Pulverized Coal Fineness Record............................................................................17
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1. Purpose
To perform initial burning adjustment on new boilers to ensure that the systems are able to operate
safely and stably during commissioning. The requirements are that the burning conditions are stable
and boilers are free of black smoke, serious coking, serious pollution and corrosion of convection flue
gas pass. The test shall ensure that 30 day reliability operation can be carried out, provide certain
operation experience for trial production and provide data for boiler performance test and normal unit
operation for reference.

2. Scope
This procedure is applicable to boiler burning adjustment and commissioning. The following systems
need be commissioned:
2.1 Adjustment of excess air factor (oxygen content):
2.2 Adjustment of burners’ swing angle and of secondary air dampers;
2.3 Adjustment of the fineness of pulverized coal;
2.4 Adjustment of primary and secondary air flowrate and flow velocity for burners;
2.5 Load distribution among burners;
2.6 Cold-state inspection of even primary air distribution among pulverized coal piping

3. Preparation Basis
3.1 Combustion Adjustment and Test Method for Coal-fire Boilers;
3.2 Instruction manuals for boiler equipments;
3.3 Manual of combustion equipment;
3.4 Manual of coal mills;
3.5 Flue-gas and air system drawings.

4. Brief Description of System and Equipment


4.1 Boiler: Model DG1025/18.3-II13, natural circulation drum boilers with four-corner tangential firing. It
has single furnace with half open arrangement of II Type, brown coal fired, single reheating, balanced
ventilation
4.2 Temperature control mode: superheated steam is desuperheated by spraying water, and the swinging
burner nozzle is used as the main way to adjust the steam temperature of the reheated steam, reducing
temperature with water spray as auxiliary.
4.3 Model HP963 coal mills are used and five coal mills are provided for each boiler (when the design
coal is fired, 4 coal mills operate and 1 coal mill is as standby).
4.4 Burner arrangement and type: Burners are arranged at four corners, the burner centerlines are
tangential to two imaginary circles of furnace centerline, of which the diameters are 548mm and 1032
mm, respectively.
4.5 Main Boiler Parameters:
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Unit BMCR TMCR TRL 75%TRL 50%TRL

Generator output MW

Flow t/h 1025 976.19 927.80 678.00 467.50

Main steam Pressure MPa 18.0 17.5 17.33 14.33 9.56

Temperature ℃ 541 541 541 541 535

Flow t/h 863.7 802.023 766.01 571.00 402.08

Inlet pressure MPa 3.99 3. 625 3.54 2.66 1.85

Outlet
MPa 3.80 3.438 3.38 2.53 1.76
Reheat pressure
steam
Inlet
℃ 329 322 320 313 318
temperature

Outlet
℃ 541 541 541 541 515
temperature

Temp. of feed water ℃ 281 275.5 273 255 234

5. Tools and Instrument for Commissioning


5.1 Walkie talkie;

5.2 Vibration measurement instrument;


5.3 Coal powder sampler
5.4 Oxygen analyzer;
5.5 Optical thermometer;
5.6 Anemometer

6. Prerequisite for Commissioning


Before formally beginning commissioning job, commissioning persons should conduct comprehensive
checks with relevant units on conditions that should be available for commissioning of this system
according to contents listed in Attachment 1 (Commissioning Condition Checklist) and make well the
records.
6.1 Open and close test for flue gas & air baffle and steam & water valves
(1) Fully opened and closed to their limit positions;
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(2) Close and open in correct direction;


(3) Correct status indication.
6.2 Cold ventilation test
(1) Primary air evenness measurement is complete;
(2) Calibration of secondary air flow measurement devices is complete;
(3) Calibration of air flow meters at coal mill inlets is complete
6.3 Interlock, protection, sequential control and audible and visual alarm test
(1) The auxiliary part has been tested;
(2) The FSSS has been tested;
(3) The interlock test for dampers is complete;
(4) The relevant audible and visual alarm tests are complete.
6.4 Fuel Oil System
(1) The static commissioning of fuel oil systems is complete;
(2) Separate operation, program-controlled startup and shutdown test of all oil guns are complete;
(3) Interlock protection test of the fuel oil systems are complete.
6.5 Pulverizing Plant
(1) Static commissioning is complete
(2) The operation test of dampers is complete;
(3) Al interlock and protection test are complete.
6.6 Ash Blowing Systems
(1) Static commissioning of all ash blowers is complete;
(2) Static commissioning of all ash blower PLCs are complete;
(3) The ash blowing steam supply safety valves have been set.
6.7 Ash Handling System
(1) The valve operation test is complete;
(2) The interlock test is complete;
(3) The PLC test is complete;
(4) Individual trial run is complete
6.8 The static commissioning of burners are complete;
6.9 The interlock test of flame scanning cooling air systems is complete;
6.10 The interlock test of turbines, boilers and electrical systems shows that the interlock relation is correct
and operation is reliable.
6.11 The roads within the commissioning site must be free of obstructions. There is adequate lighting and
reliable emergency illumination.
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6.12 Communication equipments at trial operation site are convenient and available.
6.13 Adequate fire-fighting appliances are available.
6.14 Sufficient maintenance personnel have been suitably trained.
6.15 Adequate maintenance tools and materials are available.
6.16 The tools for operation and record forms are available.
6.17 The commissioning instruments and meters are ready for use.

7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The Contractors
shall cooperate closely with each other according to their respective work responsibilities so as to
guarantee safe and effective implementation of commissioning. Work responsibilities of the
commissioning and Contractors are as follows:
7.1 Responsibilities of Commissioning Contractor
◆ Preparation and revision of commissioning procedures;

◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;

◆ Hold technical clarification meeting for commissioning;

◆ Organize the commissioning work to be carried out by various parties;

◆ Give instructions to operators in the operation;

◆ Prepare commissioning report.


7.2 Responsibilities of Installation Contractor
◆ Be responsible for individual commissioning of equipment and provide relevant record and
certificate of commissioning;
◆ Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;

◆ Be responsible for temporary coordination of local control and instruments and connection
terminals.
7.3 Responsibilities of Equipment Manufacturer
◆ Representative of manufacturer, if present on the site offering service, shall provide technical
assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator
◆ Prepare tools to be involved in operation;

◆ Prepare operation log and forms;


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◆ Operate the system and equipment according to the operating procedures and the instructions of
the commissioning personnel;
◆ Be responsible for patrol inspection, check, and normal maintenance of system and equipment;

◆ Be responsible for dealing with the accidents occurred in commissioning。


7.5 Responsibilities of Dongfang Electric
◆ Be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning.


7.6 Responsibilities of the Owner
◆ Supervise the execution of commissioning procedures;

◆ Witness the commissioning work;

◆ Accept the results of commissioning 。

8. Commissioning Procedure
In principle, adjustable parameters shall remain unchanged as possible except that the parameters of
the individual test items may be changed
8.1 Adjustment of Excess Air Factor
An excessively-large or excessively-small excess air factor will cause the increase in energy loss.
Therefore, the excess air factor should be appropriate in order to minimize thermal loss. Oxygen
content shall be adjusted mainly by changing total secondary air flow, and small secondary air
dampers shall be used as auxiliary adjustment means to ensure that combustion is carried out at an
appropriate excess air factor.
8.2 Adjustment of Burners’ Swing Angle and of Small Secondary Air Dampers
An upward-sloping burner will provide a higher furnace combustion center, higher furnace outlet gas
temperature, superheated and reheat steam temperature and cause burnout areas to move backward.
However, if the burners slope excessively upward, the burnout areas will move backward significantly
and cause more incomplete combustion loss and heat loss due to exhaust gas. In addition, a higher
furnace outlet gas temperature may cause some unfavorable effects, such as coking at furnace outlet.
When making adjustment the burner angle, the flue gas temperature deviation shall be recorded and
adjusted.
A downward-sloping burner will provide a lower furnace combustion center, lower furnace outlet gas
temperature, and lower superheated and reheat steam temperature. When the situation is more serious,
the exhaust gas temperature will be reduced and convection flue gas pass may experience
low-temperature corrosion. Therefore, the burner swing angles shall be appropriately tuned and such
adjustment shall be made together with adjustment of small secondary air dampers. If possible, ensure
that adjustment will not cause significant combustion disturbance and sharp variation in steam
temperature and pressure. If combustion is relatively concentrated and the temperature at combustion
center is high, increase the opening of some small secondary air dampers of middle layer. If
combustion is relatively decentralized and the temperature at combustion center is low, decrease the
opening of some small secondary air dampers of middle layer. If a higher steam temperature requires
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burners to slope upward, appropriately increase the opening of upper-layer small secondary air
dampers to ensure that pulverized coals are burnt out before leaving furnaces.
8.3 Adjustment of the fineness of pulverized coal
Fine pulverized coal is advantageous to combustion and however coal mills will consume more
electric energy. On the other hand, coarse pulverized coal cause more electric energy consumption and
however disadvantageous to combustion. In order to attain optimum cost efficiency, an optimum
fineness of pulverized coal shall be required also. For a newly-installed boiler, make all necessary
effort to ensure that the fineness reaches the design value (R90=28%). The fineness of pulverized coal
is adjusted mainly by adjusting coal mill separator dampers and air supply flow to coal mills. The mill
discharge separators are adjusted by 50% firstly and the optimum state is achieved gradually. If
appropriate fineness of pulverized coal can not be achieved still, comprehensive consideration shall be
given to whether the hydraulic loading force of grinding rolls are proper, by taking account of coal
mill output. Adjust the hydraulic loading force if necessary.
8.4 Adjustment of Primary and Secondary Air Flow and Velocity for Burners;
An appropriate primary and secondary air flow and velocity of burners are required to establish
normal aerodynamic field and stable combustion. An excessively-high air flow rate and velocity will
postpone ignition while an excessively-low air flow rate and velocity will cause piping clogging and
damage to burners etc. An excessively-high or excessively-low secondary air flow velocity will impair
normal combustion and reasonable excess air factor and cause combustion to become unstable. In
order to prevent primary air piping from clogged, it is necessary to ensure that certain primary air flow
rate and velocity should be maintained, primary air velocity of all burners approach their design values
and primary air flow at coal mill inlet is not lower than 60% rated flow during coal mill operation. An
appropriate secondary air flow velocity requires that certain differential pressure should be maintained
between secondary air tanks and furnace. At present, the differential pressure shall be about 700 to 900
Pa when the boiler load is more than 50% BMCR. In addition, the ratio of primary air flow rate to
secondary air flow rate is very important. In general, this ratio shall be maintained around the design
value. The ratio shall be adjusted mainly through adjustment made upon total primary and secondary
air flow. However, in any case, the primary air flow entering each coal mill shall not be lower than
65% rated value to prevent clogging.
8.5 Load Distribution among Burners;
Under high load, adjacent 3 or 4 coal mills shall run as possible. This is advantageous to combustion
and even thermal load distribution among furnaces. When coal mills are running, all pulverized coal
outlet piping at the same layer as coal mill must be put into operation.
8.6 Primary Air Evenness Measurement for Pulverized Coal Piping
A fixed orifice is designed for pulverized coal piping at the discharge of each coal mill so that the
primary air flow deviation is within ±5%.

9. Safety Measures
9.1 Safety rules for commissioning
9.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant safety rules,
wear reasonable clothing and appropriate personal protective equipments.
9.1.2 In case of any accident that damages the equipment or hurts person happened or possibly happen
during commissioning, suspend commissioning immediately and put the equipment to the lowest
energy state. Then investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning shall obey the command of commissioning personnel.
In case there is an emergency endangering personal or equipment safety, any person has the right to
stop the operating equipment immediately and report to the control room.
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9.1.4 Combustion is associated with safe and stable operation of the units. Therefore, the test shall be
organized and commanded on a uniform basis. Any individual shall not change the test procedures
without approval.
9.1.5 All persons participating in commissioning shall abide by the associated safety rules strictly to ensure
that the commissioning can be carried out safely and smoothly;
9.2 Personal Risk and Preventative Measures
9.2.1 Flame observers shall communicate frequently with CCR operators. Flame observers shall use correct
methods to avoid burns.
9.3 Equipment Risk and Preventative Measures
9.3.1 During the test, operating condition shall not exhibit significant change to avoid flameout and other
major accidents.
9.3.2 During the test, the cooperating condition shall remain stable and the furnace shall operate under
negative pressure.
9.3.3 During the test, stop ash blowing.
9.3.4 During the test, various measurement and record on the same operating condition shall be carried out
simultaneously as possible and error shall be minimized.

10. Appendix
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Appendix 1 Commissioning Condition Checklist

Remar
No. Items Requirements Result Verified by
ks

Flue gas and air Fully opened and closed to their limit
□Yes □No
baffle, steam and positions;
1 water valve Close and open in correct direction □Yes □No
Operation test
Correct status indication. □Yes □No
Primary air evenness measurement is
□Yes □No
complete
Cold ventilation Calibration of secondary air flow
2 □Yes □No
test measurement devices is complete
Calibration of air flow meters at coal
□Yes □No
mill inlets is complete
The auxiliary part has been tested; □Yes □No
Interlock, The FSSS test is complete □Yes □No
protection,
3 sequential control, The interlock test of valves and dampers
□Yes □No
audible and visual is complete
alarm test The relevant audible and visual alarm
□Yes □No
tests are complete
The static commissioning of burners are
4 Burners □Yes □No
complete;
The static commissioning of fuel oil
□Yes □No
systems is complete;
Separate operation, program-controlled
5 Fuel oil system startup and shutdown test of all oil guns □Yes □No
are complete;
Interlock protection test of the fuel oil
□Yes □No
systems are complete
The static commissioning is complete □Yes □No
The operation test of dampers are
□Yes □No
6 Pulverizing plant complete
All interlock and protection tests are
□Yes □No
complete
Static commissioning of ash blowers are
□Yes □No
complete;
Ash blowing Static commissioning of all ash blower
7 □Yes □No
Systems PLCs are complete;
The ash blowing steam supply safety
□Yes □No
valves have been set.
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Appendix1.Commissioning Condition Checklist (continued)

Remar
No. Items Requirements Result Verified by
ks
The valve operation tests
□Yes □No
are complete
The interlock test is
□Yes □No
8 Ash handling system complete;
The PLC test is complete; □Yes □No
Individual trial run is
□Yes □No
complete
Flame scanning cooling air The interlock test is
9 system complete;
□Yes □No

Combined interlock test Correct interlock relation


10 covering the turbine, boilers □Yes □No
and electrical systems Actuation reliable

The passage is clear of any


obstacle and well lighted
11 Road at trial operation site □Yes □No
Emergency lighting
reliable
Communication equipments
12 at trial operation site
Convenient and usable □Yes □No

13 Fire apparatus Sufficient □Yes □No


14 Maintenance personnel Sufficient and trained □Yes □No
Maintenance tools and
15 materials
Sufficient □Yes □No

Tools for operation and


16 record forms.
Prepared □Yes □No

Prepared
17 Test instruments and meters □Yes □No

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
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SCCTI-TS-GL-CS-004-2009A Page 13 of 17

Appendix 2 Boiler Combustion Parameter Adjustment Record

Combustion Parameter Adjustment Record


Time Electric load
Name Unit Data Name Unit Data
Main steam flow T/H Reheater outlet pressure MPa
Main steam pressure MPa Reheater outlet pressure MPa
Main steam temperature ℃ Reheater temperature ℃
1st stage desuperheating
drum pressure MPa T/H
water flow
2nd stage desuperheating
Drum level mm T/H
water flow
3rd stage desuperheating
Feed water flow T/h T/H
water flow
Feed water pressure MPa Micro water spray flow T/H
Emergency desuperheating
Temp. of feed water ℃ T/H
water flow
Flue gas temperature at
IDF current (A/B) A ℃
economizer inlet
Opening of IDF inlet Flue gas temperature at air
% ℃
damper (A/B) preheater inlet
FDF current (A/B) A Temp. of flue gas ℃
FDF dynamic blade opening
% Burner’s angle of swing %
(A/B)
Primary air fan current Primary air damper of air
A KPa
(A/B) preheater outlet
A/B primary air fan guide Secondary air tank
% KPa
blade opening A/B pressure
FD fan outlet air pressure
% Oxygen content %
(A/B)
Air preheater outlet air
KPa Primary air pressure KPa
pressure (A/B)
Coal Mill Parameters
No. of coal mill Unit A B C D E
Primary air flow at mill inlet T/H
Primary air temperature at

mill inlet
Coal feeding flow T/H
Mill outlet temperature: ℃
Differential pressure
KPa
through mill separator
Coal mill current A
Fineness of pulverized coal %
Opening of mill separator
%
damper
Commissioning Contractor: Date: Operation Contractor: Date:
Contractor: Date: Dongfang Electric: Date:
Owner Date:
PLTU 1 Jatim-Pacitan(2×315MW) Project

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SCCTI-TS-GL-CS-004-2009A Page 14 of 17

Appendix 3 Opening Record for All Small Secondary Air Dampers

Opening Record for All Small Secondary Air Dampers


Time Load
Small secondary air
Unit #1 Corner #2 Corner #3 Corner #4 Corner
damper at all layers
OFA top secondary
%
air
Secondary air at
%
Layer EE
Surrounding air at
%
Layer E
Secondary air at
%
Layer DE (oil)
Surrounding air at
%
Layer D
Secondary air at
%
Layer DD
Secondary air at
%
Layer CC
Surrounding air at
%
Layer C
Secondary air at
%
Layer BC (oil)
Surrounding air at
%
Layer B
Secondary air at
%
Layer AB (oil)
Surrounding air at
%
Layer A
Secondary air at
%
Layer AA
Commissioning Contractor: Date: Operation Contractor: Date:
Contractor: Date: Dongfang Electric: Date:
Owner Date:
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Appendix 4 Furnace Temperature Record

Furnace Temperature Record


Time Load
Position Side A Side B
Elevation (mm) 1 2 3 4 1 2 3 4

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
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Procedure
SCCTI-TS-GL-CS-004-2009A Page 16 of 17

Appendix 5 Record of Oxygen Content in Flue Gas

Record of Oxygen Content in Flue Gas


Time Load
Measurement point 1 2 3 4 5 6 7 8

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
Appendix 6 Coal Quality Record

Coal Quality Record


Testing time Recorded by
Test condition Unit 1 2 3 4 5 6
Load MW
Total moisture M %
Ash content Ag %
Fixed carbon Cg %
Volatile matter Vg %
Q Dw kcal.
combustible content in fly content %
Combustible content in slag %
Fineness of pulverized coal %

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner Date:
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SCCTI-TS-GL-CS-004-2009A Page 17 of 17

Appendix 7 Pulverized Coal Fineness Record

Fineness of Pulverized Coal


Testing time Recorded by
Remark
Test condition Unit Mill A Mill B Mill C Mill D Mill E
s
Load MW
Primary air flow at mill inlet T/H
Primary air temperature at mill inlet ℃
Coal feeding flow T/H
Outlet temperature of coal pulverizer

separator
Differential pressure through mill
KPa
separator
Coal mill current A
Fineness of pulverized coal %

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
Owner: Date:
PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s
PT.PLN(PERSERRO) 0702-00-M-01-HLB-001
DWG No.

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
DETAIL
Sichuan Electric Power PLTU 1 Jatim-Pacitan (2×315MW)
DESIGN
Commissioning & Test Institute Project
STAGE
Approva Check
Commissioning Procedure of Induced Draft Fan
l
System
Review Design
Date Scale DWG SCCTI-TS-GL-CS-005-200 REV
N/A A
No. 9A
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 2 of 22

Table of Contents
1. PURPOSE ........................................................................................................................................... 3

2. SCOPE ................................................................................................................................................ 3

3. PREPARATION BASIS .................................................................................................................... 3

4. BRIEF DESCRIPTION OF SYSTEM AND EQUIPMENT .......................................................... 3

5. TOOLS AND INSTRUMENT FOR COMMISSIONING.............................................................. 4

6. PREREQUISITE FOR COMMISSIONING................................................................................... 4

7. MEASURES FOR COMMISSIONING ORGANIZATION .......................................................... 5

8. COMMISSIONING PROCEDURE ................................................................................................. 6

9. SAFETY MEASURES..................................................................................................................... 15

9.1 Safety Rules for Commissioning...................................................................... 15

9.2 Personal Risk and Preventative Measures........................................................ 15

9.3 Equipment Risk and Preventative Measures .................................................... 15

10. APPENDIX ............................................................................................................................... 16

10.1 Appendix 1 Commissioning Condition Checklist............................................ 17

10.2 Appendix 2 Trial Operation Parameters of IDF and Its System....................... 19

10.3 Appendix 3 IDF Dampers Commissioning Record.......................................... 20

10.4 Appendix 4 Control Damper Commissioning Record of IDF and Its System . 22
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Procedure
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1. Purpose
1.1 Provide a guideline and set specifications for the commissioning work of system and
equipment so as to guarantee that the system and equipment will be able to put into operation
normally and safely.
1.2 Check electrical and I&C protection interlock devices and signal devices and confirm that
their actions are correct and reliable.
1.3 Check the operation conditions of equipment. Examine performance of system so as to find
out and eliminate possible defects.

2. Scope
This procedure is applicable for the commissioning of induced draft fan subsystem, including
such items as the confirmation of air damper, interlocking and protection test, system
commissioning and dynamic adjustment.

3. Preparation Basis
3.1 Operation manual of induced draft fan
3.2 Boiler flue gas system diagram
3.3 Control logic diagram on induced draft fan

4. Brief Description of System and Equipment


4.1 There are two operating induced draft fans. The stationary blade damper at the inlet of fan is
employed to control the pressure of boiler furnace.
4.2 Technical parameters of induced draft fan

Model of fan: AN-25/V13+2.5 Axial-flow type


Name Unit TB BMCR TMCR
3
Flow at inlet of fan m /s 290.8 246.7 239.8
3
Medium density Kg/ m 0.869 0.869 0.867
Total pressure of fan PA 5796 4456 4093
Shaft power of fan KW 1912 1251 1143
Total pressure efficiency of fan % 85.5 85.8 84.5
Rotating speed r/min 990 990 990

4.3 Technical Parameters of Motor

Model of motor YKK710-6TH-W Rated voltage 6300V


Rated power 2150 KW Rated speed 990 r/min

4.4 Technical parameters of cooling fan

Model of fan G9-19№5A Rated voltage 380V


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Procedure
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Rated power 11 KW Rated speed 2960 r/min

5. Tools and Instrument for Commissioning


5.1 Walkie talkie;
5.2 Handheld vibration measurement instrument;
5.3 Digital multimeter;
5.4 Temperature measurement meter;
5.5 Tachometer;
5.6 Sound intensity meter.

6. Prerequisite for Commissioning


Before formally beginning commissioning job system by system, commissioning persons
should conduct comprehensive checks on conditions that should be available for
commissioning of this system according to contents listed in Appendix 1 (Commissioning
Condition Checklist) and make well the records.
6.1 Environmental condition
6.1.1 Within the scope of system, the site should be level, the road should be clear, the trench cover
is complete and the environment is clean and free of sundries.
6.1.2 Within the scope of system, the plat form, ladder, handrail and guard board are complete, the
scaffolds used for construction have been demolished completely.
6.1.3 The sufficient formal illumination is provided on site, if necessary, the temporary illumination
should be installed additionally.
6.1.4 The reliable communication equipments are provided on site.
6.1.5 The sufficient firefighting appliances are provided on site.
6.2 Conditions that must be available for machinery provisions
6.2.1 The installation and heat insulation work of all the equipments, pipelines and auxiliary
systems have been completed;
6.2 The single commissioning for the induced draft fan is qualified;
6.2.3 The installation and commissioning for the cooling fan are completed;
6.2.4 The installation and commissioning for the industrial cooling water system are completed;
6.2.5 The sundries inside the induced draft fan and system are cleared clean;
6.2.6 The equipment and each valve have been tagged and named, conforming to the system.
6.2.7 Each manhole door inside the system is closed.
6.3 Necessary conditions for electrical and I&C
6.3.1 After the measuring points and measuring elements inside the system are qualified subject to
calibration, the installation and commissioning are completed and provided with the
application conditions.
6.3.2 After the commissioning for the cooling fan is competed, the favorable operation condition,
PLTU 1 BANTEN(2×315MW) Project
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Procedure
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normal parameters and the correct display of CRT state have been confirmed.
6.3.3 When single commissioning of the valve is completed, the on/off actions are normal and the
on-site location of the limit switch and display of the CRT state are correct.
6.3.4 The interlock protection alarm test for the induced draft fan system is completed.
6.3.5 The electrical test of motor is qualified, after 2 hour no-load running, the condition is
favorable and the turning direction is correct.
6.4 Other necessary conditions
6.4.1 The joint inspection is performed through organizing such related parties as construction,
Dongfang Electric, Owner and production as well as commissioning; the problems found
should be coped completely.
6.4.2 The preparation work for production and commissioning is completed; the operators should
be arranged completely and qualified via the training and examination. The operation
regulation and system diagram are reviewed and approved; the operating tools and the
operation log are prepared properly.
6.4.3 The necessary maintenance tools and materials are prepared;
6.4.4 The command and organizing system for commissioning is perfect, with explicit division of
labor.
6.4.5 The commissioning data, tools, instruments, gauge and the record list are prepared
completely;
6.4.6 The personnel on instrument control, electrical and maintenance from the installation
organization arrive at the site.
6.4.7 The disclosure work on measures is completed.

7. Measures for Commissioning Organization


This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows:
7.1 Responsibilities of Commissioning Contractor

◆ Preparation and revision of commissioning procedures;

◆ Preparation of commissioning plan;

◆ Preparation of instruments and equipment required for commissioning;

◆ Hold technical disclosure meeting for commissioning;

◆ Organize the commissioning work to be carried out by various parties;

◆ Give instructions to operators in the operation;

◆ Prepare commissioning report.


7.2 Responsibilities of Installation Contractor
◆ Be responsible for individual commissioning of equipment and provide relevant record
and certificate of commissioning;
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Procedure
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◆ Be responsible for inspection, maintenance and defect elimination of equipment under


commissioning;

◆ Prepare maintenance tools and materials necessary for commissioning;

◆ Assist the commissioning contractor in the commissioning of subsystems;

◆ Be responsible for temporary coordination of local I&C components and connection


terminals.
7.3 Responsibilities of Equipment Manufacturers

◆ Representative of manufacturer, if present on the site offering service, shall provide


technical assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator
◆ Prepare tools to be involved in operation;

◆ Prepare operation log and forms;

◆ Operate the system and equipment according to the operating procedures and the
instructions of the commissioning personnel;

◆ Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;

◆ Be responsible for dealing with the accidents occurred in commissioning。


7.5 Responsibilities of Dongfang Electric
◆ Be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.

◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning。


7.6 Responsibilities of Owner

◆ Supervise the execution of commissioning procedures;

◆ Witness the commissioning work;

◆ Accept the results of commissioning。

8. Commissioning Procedure
8.1 Cold check and transmission test of damper
8.1.1 Check the motorized or pneumatic on-off damper and enter the following data on the records:
Check whether KKS code, designation, local position indications are correct and whether the
remote operation direction and feedback are correct; the on/off time of damper, test date,
signature by person in charge of test. Refer to Appendix 4 for other contents.
8.1.2 Check the motorized or pneumatic regulating valves and enter the following data on the
records;
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Procedure
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KKS code, designation, local position indications and feedback indications corresponding to
upward command of 0%, 50%, 75%, and 100% and downward command of 100%, 75%, 50%,
and 0% respectively, confirm if local position indication is correct, test date, signature by
person in charge of test. Refer to Appendix 3 for other requirements.
8.2 Check Interlock Protection and Alarms (note: the test item on interlock protection is based on
the discuss result on logic.)
8.2.1 The power supply of the induced draft fan shall be placed in the test location to inspect the
items below:
(1) Start-up induced draft fan through computer and feedback on computer is correct;
(2) Suspending the induced draft fan through computer and feedback on computer is correct;
(3) Reliable emergency buttons
8.2.2 The interlock protection test of the induced draft fan covers:
8.2.2.1 Inspection for the opening condition of air passage

No. Test item Fixed value Results Remarks


Opening of A side air passage
(1) All the secondary dampers are in the purging location.
The inlet damper of induced draft fan A has been opened,
the stationary blade at the inlet of induced draft fan A has
(2)
not been closed properly and the outlet damper of induced
draft fan A has been opened.
The moving blade of the forced draft fan A hasn’t been
closed properly, the outlet damper of the forced draft fan A
(3) has been opened, the interconnection valve at the outlet
has been opened or the secondary damper at the outlet of
air preheater has been opened;
The single-plate flue damper at the inlet of air preheater A
(4)
has been opened or the air preheater is operating.
Opening of B side air passage
(1) All the secondary dampers are in the purging location.
The inlet damper of induced draft fan B has been opened,
the stationary blade at the inlet of induced draft fan B has
(2)
not been closed properly and the outlet damper of induced
draft fan B has been opened.
The moving blade of the forced draft fan B hasn’t been
closed properly, the outlet damper of the forced draft fan
(3) B has been opened, the interconnection valve at the outlet
has been opened or the secondary damper at the outlet of
air preheater B has been opened;
The single-plate flue gas damper at the inlet of air
(4) preheater B has been opened or the air preheater B is
operating.
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Procedure
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8.2.2.2 Inspection for allowable condition of induced draft fan A (B)

No. Test item Fixed value Results Remarks


Inspection for allowable condition of induced draft fan A
(1) Induced draft fan A is free of tripping condition;
(2) Opening of B side air passage
The air preheater A is operating and the flue gas damper
(3)
at the inlet has been opened.
(4) The stationary blade at the inlet of induced draft fan A
has been closed;
The electric damper at the inlet of induced draft fan A
(5)
has been opened;
The control damper at the inlet of induced draft fan A has
(6)
been closed;
The electric damper at the inlet of induced draft fan A
(7)
has been closed;
(8) The temperature of bearing for the induced draft fan A is
normal;
The temperature of motor bearing for the induced draft
(9)
fan A is normal;
The temperature of stator coil of motor for the induced
(10)
draft fan A is normal;
(11) Any cooling fan of the induced draft fan A is operating
(12) Free of request of FSSS natural ventilation
Inspection for allowable condition of induced draft fan B
(1) Induced draft fan B is free of tripping condition;
(2) Opening of A side air passage
The air preheater B is operating and the flue gas damper
(3)
at the inlet has been opened.
(4) The electric damper at the outlet of induced draft fan B
has been opened;
The control damper at the inlet of induced draft fan B
(5)
has been closed;
The electric damper at the inlet of induced draft fan B
(6)
has been closed;
The temperature of bearing for the induced draft fan B is
(7)
normal;
(8) The temperature of motor bearing for the induced draft
fan B is normal;
(9) The temperature of stator coil of motor for the induced
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Procedure
SCCTI-TS-GL-CS-005-2009A Page 9 of 22

draft fan B is normal;


(10) Any cooling fan of the induced draft fan B is operating
(11) Free of request of FSSS natural ventilation

8.2.2.3 Inspection on tripping condition for the protection interlinking of induced draft fan

No. Test item Fixed value Results Remarks


Tripping condition of induced draft fan A
After the induced draft fan A operates for 60s, the electric
(1)
damper at the outlet of induced draft fan A is closed;
After the induced draft fan A operates for 60s, the electric
(2)
damper at the inlet of induced draft fan A is closed;
The bearing temperature of the induced draft fan A is high
(3)
high.
The motor bearing temperature of the induced draft fan A
(4)
is high high.
The vibration of bearing in X-direction at the driving end 6.3mm/s
(5)
of induced draft fan A is high
The vibration of bearing in Y-direction at the driving end 6.3mm/s
(6)
of induced draft fan A is high
The vibration of bearing in X-direction at the non-driving 6.3mm/s
(7)
end of induced draft fan A is high
The vibration of bearing in Y-direction at the non-driving 6.3mm/s
(8)
end of induced draft fan A is high

(9)
The furnace pressure of FSSS is low;
(10) Emergency button action;
After the induced draft fan A operates for 60s, two cooling
(11)
fans suspends completely;
The stationary blade is greater than 15%, and the induced
(12)
draft fan A is stalling.
(13) Air preheater A suspends
Tripping condition of induced draft fan B
After the induced draft fan B operates for 60s, the electric
(1)
damper at the outlet of induced draft fan B is closed;
After the induced draft fan B operates for 60s, the electric
(2)
damper at the inlet of induced draft fan B is closed;
The bearing temperature of the induced draft fan B is high
(3)
high.
(4) The motor bearing temperature of the induced draft fan B
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 10 of 22

is high high.
The vibration speed of motor bearing for the induced draft
(5)
fan B is high high.
The vibration of bearing in X-direction at the driving end
(6)
of induced draft fan B is high high

(7) The vibration of bearing in Y -direction at the driving end


of induced draft fan B is high high
(8) The vibration of bearing in X-direction at the non-driving
end of induced draft fan B is high high
The vibration of bearing in Y-direction at the non-driving
(9)
end of induced draft fan B is high high
(10) The furnace pressure of FSSS is low low;
(11) Emergency button action;
After the induced draft fan operates for 60s, two cooling
(12)
fans suspends completely;
(13)
The stationary blade is greater than 15%, and the induced
draft fan B is stalling.
(14) Air preheater B suspends

8.2.3 Inspection for alarm condition of induced draft fan

No. Test item Fixed value Results Remarks


Alarm condition of induced draft fan A
(1) The bearing temperature of the induced draft fan A is high.
The motor bearing temperature of the induced draft fan A
(2)
is high.
The motor stator temperature of the induced draft fan A is
(3)
high.
(4) The vibration speed of motor bearing for the induced draft
fan A is high.
The vibration of bearing in X-direction at the driving end
(5)
of induced draft fan A is high
The vibration of bearing in Y-direction at the driving end
(6)
of induced draft fan A is high
The vibration of bearing in X-direction at the non-driving
(7)
end of induced draft fan A is high
(8) The vibration of bearing in Y-direction at the non-driving
end of induced draft fan A is high
(9) Induced draft fan A is stalling.
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 11 of 22

Alarm condition of induced draft fan B


The bearing temperature of the induced draft fan B is
(10)
high.
The motor bearing temperature of the induced draft fan B
(12)
is high.
The motor stator temperature of the induced draft fan B is
(13)
high.
(14) The vibration speed of motor bearing for the induced draft
fan B is high.
The vibration of bearing in X-direction at the driving end
(15)
of induced draft fan B is high
The vibration of bearing in Y-direction at the driving end
(16)
of induced draft fan B is high
The vibration of bearing in X-direction at the non-driving
(17)
end of induced draft fan B is high
(18) The vibration of bearing in Y-direction at the non-driving
end of induced draft fan B is high
(19) Induced draft fan B is stalling.

8.2.2.4 Interlock test for cooling fan of induced draft fan

No. Test item Fixed value Results Remarks


(1) 1# cooling fan of induced draft fan A
1) Startup permissive conditions: in remote control location

2) Shutdown permissive conditions (or):


Shutdown of induced draft A
2# cooling fan of induced draft fan A is operating
3) Interlock startup conditions:
2# cooling fan is operating and the bearing temperature of
induced draft A is greater than 90℃, 1# cooling fan is
started by means of interlock.
Emergency tripping for 2# cooling fan; 1# cooling fan is
started by means of interlock.
Starting the 1# cooling fan in program control
(2) 2# cooling fan of induced draft fan A
1) Startup permissive condition: in remote control location

2) Shutdown permissive conditions (or):


Shutdown of induced draft A
1# cooling fan of induced draft fan A is operating
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 12 of 22

3) Interlock startup conditions:


1# cooling fan is operating and the bearing temperature of
induced draft A is greater than 90℃, 2# cooling fan is
started by means of interlock.
Emergency tripping for 1# cooling fan; 2# cooling fan is
started by means of interlock.
Starting the 1# cooling fan in program control
(3) 1# cooling fan of induced draft fan B
1) Startup permissive conditions : in remote control
location
2) Shutdown permissive conditions (or):
Suspension of induced draft B
2# cooling fan of induced draft fan B is operating
3) Interlock startup conditions:
2# cooling fan is operating and the bearing temperature of
induced draft A is greater than 90℃, 1# cooling fan is
started by means of interlock.
Emergency tripping for 2# cooling fan; 1# cooling fan is
started by means of interlock.
Starting the 1# cooling fan in program control
(4) 2# cooling fan of induced draft fan B
1) Startup permissive conditions : in remote control
location
2) Shutdown permissive conditions (or):
Shutdown of induced draft B
1# cooling fan of induced draft fan B is operating
3) Interlock startup conditions:
1# cooling fan is operating and the bearing temperature of
induced draft B is greater than 90℃, 2# cooling fan is
started by means of interlock.
Emergency tripping for 1# cooling fan; 2# cooling fan is
started by means of interlock.
Starting the 2# cooling fan in program control

8.2.2.5 The damper at the inlet and outlet of induced draft fan as well as the interlock test of
stationary blade

No. Test item Fixed value Results Remarks


(1) This side induced draft fan starts and operates; 30s is
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 13 of 22

delayed to lock and open the inlet damper and outlet


damper of this side induced draft fan; meanwhile, if
another side induced draft fan doesn’t operate, the inlet
damper and outlet damper as well as the stationary blade
of another side induced draft fan are closed by means of
interlock.
The two air induced draft fans are outage, 135s is delayed
for FSSS protection to lock and open the inlet damper and
(2)
out let damper as well as the stationary blade for two
induced draft fans.
(3) This side air induced draft fan is outage; the air induced
draft at other side is operating, the inlet damper and outlet
damper as well as the stationary blade for this side
induced draft fan are closed by means of interlock

8.2.2.6 Interlock test for the interconnection valve at the outlet of electric precipitator

No. Test item Fixed value Results Remarks


(1) Conditions for interlock opening:
(2) Induced draft A and B suspend uniformly, delayed for 80s.
(2) Conditions for interlock close ( following conditions or)
The air preheater A suspends and the induced draft fan B
operates or
The air preheater A suspends and the induced draft fan A
operates or
The induced draft fan A suspends for 65s and the induced
draft fan B operates , and

The flue gas damper actuator at the outlet of induced draft


fan A is not closed, and the stationary blade at inlet of
induced draft A is not closed properly or the induced draft
B suspends for 65s.
The induced draft fan A is operating, the actuator of the
flue gas damper at the outlet of induced draft fan B is not
closed and the stationary blade at the inlet of induced draft
B is not closed properly.

8.2.2.7 Procedure on sequence control startup and shutdown for the induced draft fan

No. Test item Fixed value Results Remarks


Procedure on sequence control startup for the induced draft fan A
(1) Step 1: start the cooling fan of induced draft fan A
Step 2: close the inlet damper of induced draft fan A;
(2) The stationary blade at the inlet of induced draft fan A is
closed up to the minimum location;
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 14 of 22

Open the outlet damper of induced draft fan A


(3) Step 3: start the induced draft fan A
(4) Step 4: open the inlet damper of induced draft fan A
Procedure on sequence control shutdown for the induced draft fan A
Step 1: the stationary blade at the induced draft fan A is
(1)
located in the minimum location;
(2) Step 2: induced draft fan A suspends
(3) Step 3: close the electric dampers at the inlet and outlet
of the induced draft fan A
Procedure on sequence control startup for the induced draft fan B
(1) Step 1: start the cooling fan of induced draft fan A
Step 2: close the inlet damper of induced draft fan A;
The stationary blade at the inlet of induced draft fan A is
(2)
closed up to the minimum location;
Open the outlet damper of induced draft fan A
(3) Step 3: start the induced draft fan A
(4) Step 4: open the inlet damper of induced draft fan A
Procedure on sequence control shutdown for the induced draft fan B
Step 1: the stationary blade at the induced draft fan A is
(1)
located in the minimum location;
(2) Step 2: induced draft fan A suspends
(3) Step 3: close the electric dampers at the inlet and outlet
of the induced draft fan A

8.3 Commissioning and shutdown of the induced draft fan and system
8.3.1 Check to be completed prior to system startup
8.3.1.1 Various interlock tests for the induced draft fan and system is confirmed to be qualified;
8.3.1.2 The power transmission of the inlet and outlet dampers of the induced draft fan as well as the
inlet regulating damper is confirmed and the switch is flexible; and the local openness is
consistent with the display of CRT.
8.3.1.3 The qualified lubrication oil has been filled for various bearings of the induced draft fan;
8.3.1.4 The commissioning conditions are confirmed to be provided for the cooling fan;
8.3.1.5 Various kinds of meters for the fan has been confirmed to be put into operation;
8.3.2 Commissioning for the induced draft fan and the systems
8.3.2.1 Start one cooling fan;
8.3.2.2 The allowable conditions for starting of the induced draft fan are confirmed to be met;

8.3.2.3 Start up induced draft fan;


8.3.2.4 Open the greater damper at inlet of fan and the outlet damper;
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 15 of 22

8.3.2.5 Adjust the stationary blade of fan and control the pressure of furnace;
8.3.3 Suspension of air draft fan and its system
8.3.3.1 The stationary blade of the fan is closed up to the minimum location;
8.3.3.2 Suspend the fan;
8.3.3.3 Close the inlet and outlet dampers at inlet of fan
8.3.3.4 Suspend the cooling fan in delay;
8.4 Operation for the system during startup of complete set of system;
Based on the dead load stage, on-load stage and full load stage as well as the 30d reliable
operating stage, the operation reliability of the system should be tested;
(1) Dynamic regulation of system:in the process of system commissioning, especially when
the negative pressure adjusting of the furnace is operated, the monitoring on the
equipment should be strengthened to ensure that the system is in the optimal operation
state.

(2) Complete trial operation record:The main parameters during starting the commissioning
refer to Appendix 2;

9. Safety Measures
9.1 Safety Rules for Commissioning
9.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant
safety rules on site, and wear reasonable clothing and appropriate personal protective
equipments.
9.1.2 In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Then investigate the cause and take corrective measures.
9.1.3 The parties participating in the commissioning shall obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.1.4 All professional staffs shall be on respective duties during the whole commissioning to
guarantee the safe operation of equipments.
9.2 Personal Risk and Preventative Measures
9.2.1 Injuries might be caused by rotating equipment during commissioning or test. Therefore,
special care must be taken during work and do not touch the rotating components with tools
or your hand。
9.3 Equipment Risk and Preventative Measures
9.3.1 When the induced draft fan and the system start up the commissioning for the first time, the
relevant personnel must be designated to strictly monitor the equipment site, and the reliable
communication means shall be employed to contact with the central control room.
9.3.2 When the induced draft fan is commissioning, the start time and current should be strictly
monitored; if the start time is too long or the current swings abnormally, stop the operation
timely;
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 16 of 22

9.3.3 When starting the fan, the rotating direction should be noticed, if the turning direction is
opposite, suspend the operation timely;
9.3.4 Take notice of monitoring the variation of such parameters as current, vibration and bearing
temperature to avoid producing the severe accidents.

10. Appendix
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 17 of 22

10.1 Appendix 1 Commissioning Condition Checklist

No. Items Requirements Result Verified by Remarks


1. Environmental conditions
Site, road and
(1) Flat, clear and clean □Yes □No
environment
Platform, ladder, Complete
(2) handrail, guard plate and □Yes □No
construction scaffold Demolishing

(3) Illumination Sufficient □Yes □No


Communication
(4) Reliable □Yes □No
equipment
The quantity is sufficient and
(5) Fire apparatus □Yes □No
application is convenient
2. Maintenance conditions
Installation and heat
(1) All fulfilled □Yes □No
insulation work
Commissioning of fan
(2) Qualified □Yes □No
monomer
(3) Lubrication oil of bearing Completing the filling □Yes □No
Commissioning of
(4) Qualified □Yes □No
cooling fan
Debugging is completed and
Industrial cooling water
(5) commissioning can be □Yes □No
system
performed.
Inner sundries ( including
(6) the boiler body and Completing the clearing □Yes □No
electric precipitator
(7) Equipment and valve Listing, correct name □Yes □No
(8) Manhole door Closed fully □Yes □No
Electrical and I&C
3.
condition
Measuring points and the The calibration is qualified and
(1) □Yes □No
measuring gauge the indication is correct
The operation status is
Control for the cooling
(2) favorable, the display of status is □Yes □No
fan
correct
After completing the
commissioning, the action is
(3) Single valve □Yes □No
normal, the display of status is
correct.
PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 18 of 22

Interlock protection and


(4) Test eligible □Yes □No
alarm
The test is qualified, subject to
2-h no-loading operation, the
(5) Electrical test of motor □Yes □No
condition is favorable and the
rotary direction is correct.
4. Other conditions
Inspection work of Completed, the treatment of
(1) □Yes □No
system defects is completed;
The operators are provided
completely, the operation tools
(2) Production preparing are prepared properly and the □Yes □No
operation log is prepared
properly.
Overhaul tools and
(3) Complete □Yes □No
materials
Command and Perfect, the division of work is
(4) □Yes □No
organization system explicit.
Commissioning data,
(5) tools, instruments, meters □Yes □No
and record form, Preparation is complete

Sufficient quantity and qualified


(6) Maintenance personnel □Yes □No
training
(7) Disclosure of measures Fulfilled □Yes □No

Commissioning Contractor: Date: Operation Contractor: Date:

Contractor: Date: Dongfang Electric: Date:


PLTU 1 BANTEN(2×315MW) Project
Procedure of Induced Draft Fan System REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-005-2009A Page 19 of 22

10.2 Appendix 2 Trial Operation Parameters of IDF and Its System


Trial Operation Parameters of IDF and Its System

No. Item Unit Data Remarks

1 Open position of control damper at inlet of IDF A %

2 Open position of control damper at inlet of IDF B %

3 Motor current of IDF A A

4 Motor current of IDF B A

5 The inlet air pressure of IDF A KPa

6 The inlet air pressure of IDF B KPa

7 The difference pressure between outlet and inlet of IDF A KPa

8 The difference pressure between outlet and inlet of IDF B KPa

9 Bearing vibration of IDF A mm/s

10 Bearing vibration of IDF B mm/s

11 Bearing temperature of IDF A ℃

12 Bearing temperature of IDF B ℃

13 Motor bearing temperature of IDF A ℃

14 Motor bearing temperature of IDF B ℃

15 Motor winding temperature of IDF A ℃

16 Motor winding temperature of IDF B ℃

17 Outlet gas temperature ℃


PLTU 1 BANTEN(2×315MW) Project

Procedure of Induced Draft Fan System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-005-2009A Page 20 of 22

10.3 Appendix 3 IDF Dampers Commissioning Record


IDF Dampers Commissioning Record

Local Remote Time Signatu Remark


KKS code Name position Remote Date
re s
indication
Direction Feedback Direction Feedback

X0HNA11AA001aXB Inlet damper1, ID fan A

X0HNA11AA001bXB Inlet damper2, ID fan A

X0HNA12AA001aXB Outlet damper1, ID fan A

X0HNA12AA001bXB Outlet damper2, ID fan A

X0HNA21AA001aXB Inlet damper1, ID fan B

X0HNA21AA001bXB Inlet damper2, ID fan B

X0HNA22A001aXB Outlet damper1, ID fan B

X0HNA22A001bB Outlet damper, ID fan B

ELEC PRECIPITATOR
X0HNA13AA001XB INTERCONNECTING MOTOR
SHUT-OFF DAMPER

ELEC PRECIPITATOR A OUTL


X0HNA11AA001aXB
MOTOR SHUT-OFF DAMPER 1
PLTU 1 BANTEN(2×315MW) Project

Procedure of Induced Draft Fan System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-005-2009A Page 21 of 22

ELEC PRECIPITATOR A OUTL


X0HNA11AA001bXB
MOTOR SHUT-OFF DAMPER 2

ELEC PRECIPITATOR A OUTL


X0HNA21AA001aXB
MOTOR SHUT-OFF DAMPER 1

ELEC PRECIPITATOR A OUTL


X0HNA21AA001bXB
MOTOR SHUT-OFF DAMPER 2

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
PLTU 1 BANTEN(2×315MW) Project

Procedure of Induced Draft Fan System REV A


Commissioning Procedure
SCCTI-TS-GL-CS-005-2009A Page 22 of 22

10.4 Appendix 4 Control Damper Commissioning Record of IDF and Its System
Control Damper Commissioning Record of IDF and Its System

KKS Feedback corresponding to input value while rising and falling


Name Date Result Signature Remarks
KKS code 0% 25% 50% 75% 100% 75% 50% 25% 0%

X0HNC11AA101XB The inlet control


damper of IDF A
The inlet control
X0HNC12AA01XB
damper of IDF B

Commissioning Contractor: Date: Operation Contractor: Date:


Contractor: Date: Dongfang Electric: Date:
PLTU 1 Jatim-Pacitan (2×315MW) Project

Commissioning Procedure

Owner’s DWG
PT.PLN(PERSERRO)
No.
0702-00-M-01-QH-001

PT REKADAYA PT.PLN(PERSERRO)
ELEKTRIKA JAVA MANAJEMEN KONSTRUKSI
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE
ENERGY
SiChuan Electric Power DETAIL
PLTU 1 Jatim-Pacitan (2×315MW)
Commissioning & Test DESIGN
Project
Institute STAGE
Approval Check
Review Design Procedure of Start-up Boiler
Date Scale N/A DWG No. SCCTI-TS-GL-CS-006-2009A REV A
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 2 of 40

Table of Contents

1. Purpose ............................................................................................................. 3
2. Scope .................................................................................................................. 3
3. Preparation Basis ................................................................................................ 3
4. Brief Description of System and Equipment...................................................... 3
5. Tools and Instrument for Commissioning .......................................................... 4
6. Prerequisite for Commissioning ......................................................................... 4
7. Measures for Commissioning Organization....................................................... 7
8. Commissioning Procedure.................................................................................. 9
9. Safety Measures................................................................................................ 28
9.1 Safety rules for commissioning ........................................................................ 28
9.2 Personal Risk and Preventative Measures........................................................ 29
9.3 Equipment Risk and Preventative Measures .................................................... 29
10. Appendix .......................................................................................................... 30
10.1 Appendix 1 Commissioning Condition Checklist............................................ 31
10.2 Appendix 2 Format for Trial Run Record ........................................................ 36
10.3 Appendix 3 Pressure boosting curve-boiling out ............................................. 37
10.4 Appendix 4 Pipeline Blowing System Diagram............................................... 38
10.5 Appendix 5 Check list of dampers ................................................................... 39
10.6 Appendix 6 Check List of Control Dampers.................................................... 40
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 3 of 40

1. Purpose
1.1 Provide a guideline and set specifications for the commissioning work of system and
equipment so as to guarantee that the system and equipment will be able to put into operation
normally and safely.
1.2 Check the reliability of electric and I&C interlock protection and signal device.
1.3 Check the operation conditions of equipment. Examine performance of system so as to find
out and eliminate possible defects.

2. Scope
The procedure is applicable to commissioning of startup boiler, including check and
confirmation of adjustment condition, valve baffle test, interlock protection test, drying,
boiling, pipe blowing and steam tightness test of startup boiler, safety valve calibration,
normal operation and shutdown of the boiler.

3. Preparation Basis
3.1 Operation Manual for Startup Boiler

4. Brief Description of System and Equipment


4.1 Brief introduction of the System
One 40t/h oil-fired start-up boiler, produced by Jiangsu Shuangliang Boiler Co., Ltd., is
equipped in PLTU 1 Jatim-Pacitan (2×315MW) Project. Model: SZS40-1.25/350-YC water
tube oil-fired package boiler.
4.2 Main Technical Specifications of System Device
4.2.1 Main Technical Specifications of Boiler:

No. Name Unit Values

1 Boiler Parameter

(1) Boiler Maximum Continuous Rating T/h 40

(2) Outlet Steam Pressure MPa 1.25

(3) Outlet Steam Temperate ℃ 350

(4) Inlet Water Temperature of Economizer ℃ 20

(5) Temp of flue gas ℃ ≤160

(6) Oil Pressure of Furnace MPa 5.3

2 Technical Performance

(1) Boiler Efficiency % 92.7


PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 4 of 40

No. Name Unit Values

(2) Gross Power of Supporting Auxiliaries kW 165

(3) Load Change Scope %BMCR 30~100

(4) Steam Temperature Deviation Range ℃ 345~370

(5) Boiler Blowdown Rating % ≤2

Split type atomizer


(6) Type and Arrangement of Burner / burner, single and front
wall arrangement

4.2.2 Type of Steam Boiler Auxiliaries


(1) Forced draft fan: supplied by boiler manufacturer, GMB-32, 43000m3/h, 6000pa,
110KW, 380v
(2) Water feed pump: supplied by boiler manufacturer, DG46-30×8, 46m3/h, 2.0Mpa,
55KW, 380v
(3) Deaerator: supplied by boiler manufacturer, QR40, 25m3, 40T/h
(4) Blowdown flash tank: supplied by boiler manufacturer, DP-3.5, 3.5 m3, 127℃

5. Tools and Instrument for Commissioning


5.1 Walkie talkie;
5.2 Handheld vibration meter;
5.3 Digital multimeter;
5.4 Handheld thermodetector

6. Prerequisite for Commissioning


Before formally beginning system commissioning, commissioning persons should conduct
comprehensive checks on conditions that should be available for commissioning of this
system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and
make well the records.
6.1 Prerequisite Required before Trial Operation of System
6.1.1 Flue Gas and Air System
(1) Boiler air pressure test has been successfully completed through acceptance or each air
leakage has been treated.
(2) Boiler proper and flue gas duct have been assembled and insulated.
(3) Individual commissioning and subsystem commissioning of forced draft fan have been
completed.
(4) All dampers of flue gas and air systems have been inspected, adjusted and accepted.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
SCCTI-TS-GL-CS-006-2009A Page 5 of 40

6.1.2 Fuel Oil System


(1) System has been assembled and individual commissioning has been completed.
(2) System hydraulic pressure test and water flushing has been completed successfully.
(3) Compressed air pipeline and valves for blowing should be assembled and tested.
(4) All motorized valves and pneumatic valves for systems have been tested and accepted.
(5) The burner has been assembled and tested.
(6) All interlock protection simulation test for systems have been successfully completed
(7) The ON/OFF tests for all oil guns and high-energy igniters have been successfully
completed.
(8) Static commissioning for all flame detectors has been completed.
6.1.3 Boiler Proper
(1) Boiler proper have been installed, insulated and accepted;
(2) Individual commissioning and interlock protection test for water feed pump have been
completed.
(3) Hydrostatic tests of the boilers have been successfully completed;
(4) The drain, vent, blowdown and nitrogen charging systems of the boilers have been
installed and insulated. All motorized valves have been tested and accepted.
(5) After hydrostatic tests, hydraulic valve spools have been removed from all safety valves
of the drums and superheaters, the safety valves have been restored to original state or
states. Blind plates have been removed from steam and water systems.
(6) Spring supports and hangers of steam and water pipeline are complete and in good order
and pins have been removed.
(7) All motorized valves and pneumatic valves on all steam and water pipeline have been
tested and accepted.
(8) The parties check jointly the boiler proper expansion systems to confirm that boiler
expansion is not restrained and all expansion indicators are complete and reset to zero
points.
(9) Ladders, platforms and railing on boiler proper are complete and illuminated sufficiently
and the boiler proper has been cleaned thoroughly.
(10) Drum level gauges have been installed, the level is indicated correctly.
(11) Boiler water samplers and dosing systems have been installed, inspected and accepted
correctly.
(12) Feed water system, desuperheating water systems have been installed and insulated. All
motorized valves and pneumatic valves have been tested.
(13) All manholes and access doors on the boiler proper are complete and closed;
6.1.4 Soot Blower Systems
(1) Soot blowers and their pipeline in boiler proper have been installed and insulated.
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(2) All motorized valves and pneumatic valves on steam supply pipeline for soot blowers
have been installed and tested.
(3) Soot blowers' local operation is safe and reliable. The blowers are ready for use at any
time.
6.1.5 Compressed Air System
(1) Instrument& service air compressors have passed commissioning individually or as a
subsystem and are ready for use.
6.1.6 Fire Protection System
(1) All fire fighting facilities are complete, fire water tests have been successfully
completed and the systems are at standby state.
(2) Fire fighting equipments have been equipped at boiler house, control room and place
with fuel oil systems.
6.1.7 Industrial Water System
(1) Industrial water systems have been installed and hydrostatic tests have been successfully
completed.
(2) Commissioning of industrial water pumps and industrial water subsystems have been
completed and pumps and systems are ready for operation.
6.1.8 Chemical Water System
(1) The chemical system is able to supply water continuously.
(2) Commissioning of make-up water systems has been completed.
6.2 Conditions that must be available with electrical and I&C
(1) Cold commissioning of the boiler FSSS (fuel oil systems) has been completed
1) Furnace blowing conditions have been checked and tested;
2) Fuel oil OFT tests and interlock test (performed after the OFT test) have been
completed;
3) The fuel oil leak test has been completed;
4) Combustion management systems for all oil guns have been tested.
(2) Sequence control, interlock and protection test of each auxiliary device has been
completed;
1) Starting conditions, tripping conditions, program-controlled startup and
program-controlled shutdown of forced draft fans (A/B)
2) Starting conditions, tripping conditions, program-controlled startup and
program-controlled shutdown of water feed pump (A/B)
(3) Electric and I&Cs have been calibrated and are accurate.
(4) For flue gas and air systems, measuring points of air temperature and pressure, furnace
negative pressure, pressure switch, flue gas temperature and pressure of heating surface
of different grade have been installed and are ready for operation.
(5) For steam and water systems, measuring points of drum pressure, superheater pressure,
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steam temperature, feed water pressure, temperature and flow, steam flow and water
level meter with electric contacts have been installed and tested and are ready for
operation.
(6) For fuel oil system, measuring points of fuel oil pressure and temperature, flow meters,
compressed air pressure have been installed, tested and are ready for operation.
(7) Measuring points of auxiliary current, bearing temperature and vibration have been
installed, tested and are ready for operation.
(8) Commissioning of various protections, alarms and visual and audio signals has been
completed and they are able to generate alarms properly.
6.3 Conditions Required for Environment
(1) The field is leveling; road is clear; cover on trenches are complete; wastes have be
cleared.
(2) Platforms, ladders, railings protecting sheets are complete; construction scaffold have be
removed.
(3) Site is sufficiently illuminated. Temporary illumination can be arranged if necessary.
(4) Communication device is complete. Reliable communication equipment should be
equipped.
6.4 Other Conditions Required
(1) The construction contractor, builder, Owner, Supervisor, Manufacturer and testing
agency inspect the entire units thoroughly to confirm that the unit is ready for ignition.
Problem found must be solved immediately, if any.
(2) Preparation for trial operation has been completed and operators have been assigned,
trained sufficiently and examined. Operation procedures and system drawings have been
reviewed and approved and operating tools and log are available.
(3) Chemical products and material required for commissioning have been prepared.
Sufficient amount of chemical water, fuel oil and coal have been prepared according to
the design requirements.
(4) Necessary maintenance tools and materials are prepared.
(5) A sound commissioning management organization has been established and the
responsibilities have been clearly defined.
(6) Commissioning material, tools, instrument and record lists have been prepared.
(7) Instrument control, electric and engineering personnel are on site.
7. Measures for Commissioning Organization
This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows:
7.1 Responsibilities of Commissioning Contractor
Preparation and revision of commissioning procedures;
Preparation of commissioning plan;
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Preparation of instruments and equipment required for commissioning;


Hold technical disclosure meeting for commissioning;
Organize the commissioning work to be carried out by various parties;
Give instructions to operators in the operation;
Prepare commissioning report.
7.2 Responsibilities of Installation Contractor
Be responsible for individual commissioning of equipment and provide relevant record and
certificate of commissioning;
Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;
Prepare maintenance tools and materials necessary for commissioning;
Assist the commissioning contractor in the commissioning of subsystems;
Be responsible for temporary coordination of local I&C components and connection
terminals.
7.3 Responsibilities of Equipment Manufacturers
Representative of manufacturer, if present on the site offering service, shall provide technical
assistance during equipment commissioning.
7.4 Responsibilities of Plant Operator
Prepare tools to be involved in operation;
Prepare operation log and forms;
Operate the system and equipment according to the operating procedures and the instructions
of the commissioning personnel;
Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;
Be responsible for dealing with the accidents occurred in commissioning。
7.5 Responsibilities of Dongfang Electric
◆ Be responsible for supervision and control over commissioning work;

◆ Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
◆ Participate in and witness the commissioning work;

◆ Organize analysis and settlement of major technical issues in commissioning。


7.6 Responsibilities of Owner
◆ Supervise the execution of commissioning procedures;

◆ Witness the commissioning work;

◆ Accept the results of commissioning。


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8. Commissioning Procedure
8.1 Test of Valves
(1) Test and accept motorized (solenoid) on off valve, and record data.
(2) Test and accept pneumatic on off valve and record data.
(3) Test and accept pneumatic adjustable valve and record data. SeeAppendix 5 and 6.
8.2 Interlock protection and alarm check (note: interlock protection test is subject to the results of
logic discussion)
(1) Put the power supply of fans and water feed pump at testing position
(2) Check the flowing items:
(3) Start the fans or water feed pump on computer and the feedback on computer is right.
(4) Stop the fans or water feed pump on computer and the feedback on computer is right.
(5) Operation of the emergency button is reliable.
(6) Interlock protection of start-up boiler system is as the following:

No. Test item Fixed value Results Remarks


1. MFT Condition
Manual MFT (from the host computer or program
(1)
control cabinet)
(2) Stop forced draft fan s
(3) Furnace pressure high (2 of 3 logic)
(4) Furnace pressure low (2 of 3 logic)
(5) Drum level high (1 of 2 logic) +150 mm
(6) Drum level low (1 of 2 logic) -150 mm
(7) Failure of fuel
(8) Fuel pressure low (1.5MPa)
(9) Drum pressure high; time delay 10 seconds (1.8 MPa)
(10) Emergency flameout in whole furnace
2. MFT reset
(1) Reset button of host computer
(2) Secondary reset button of program control cabinet
3. Furnace blowing condition
Normal flame detector cooling air pressure lasts for
(1)
20 seconds
(2) Air volume over than 30% and less than 40%
(3) Put forced draft fan s into operation
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(4) No flame on all flame detector


(5) MFT condition does not exist
(6) All dampers are open. (more than 30%)
(7) All oil inlet valve are off.
(8) Close master fuel oil valve in place
Forced draft fan tripping condition (all conditions
4.
are met)
(1) Furnace pressure high (2/3 logic)
MFT, close all oil valve in place, air volume over
(2)
30%, time delay 5 minutes.
(3) No flame on oil burner.
Interlock in operation, forced draft fan trip and burner
(4)
trip by interlock
Start condition of forced draft fan: (all conditions
5.
are met)
(1) All dampers are closed (less than 10%)
(2) Send command to start fan
(3) Power program control cabinet permit
Stop condition of forced draft fan: (all conditions
6.
are met)
(1) All dampers are closed (less than 10%)
Send command to stop fans or the tripping condition
(2)
of fans meets or high current of fan
Forced draft fan interlock in operation; close master
(3) oil valves in place or the fan interlock is not in
operation.
(4) Power program control cabinet permit
Start conditions of master oil inlet valves (all
7.
conditions are met)
(1) Command to open oil valves
(2) Close all oil inlet valves in place
(3) No MFT
(4) Oil inlet valves are not opened in place
Close conditions of master oil inlet valves (all
8.
conditions are met)
(1) Command to close oil valves or MFT
(2) Oil inlet valves are not closed in place
9. Start conditions of master oil return valves (all
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conditions are met)


(1) Command to open oil valves
(2) All oil inlet valves are closed in place
(3) No MFT
(4) Oil return valves are not opened in place
Close conditions of master oil return valves (all
10.
conditions are met)
(1) Command to close oil valves or MFT
(2) Oil return valves are not closed in place
11. Permit to feed oil
(1) Open fuel oil master valves in place
(2) No MFT
Fuel oil pressure: not low, over 5 minutes (>1.5,<
(3)
3.0)
(4) No steam boiler OFT
(5) No MFT command exists
Blowing is completed or the boiler is put into
(6)
operation
(7) Steam drum water level normal
12. Boiler OFT (any condition is met)
All oil inlet valves, fuel oil valves are not closed in
(1)
place, fuel oil pressure low
All oil inlet valves are not closed in place, fuel oil
(2)
master valves are closed in place.
13. Open of main steam valves (all conditions are met)
(1) Send command to open valves
(2) Power supply of main steam valves is not broken
(3) State of program control
(4) Main steam valves are not opened in place
14. Main steam valves (all conditions are met)
(1) Send command to close valves
(2) Power supply of main steam valves is not broken
(3) State of program control
(4) Main steam valves are not closed in place
Open of steam release valves (all conditions are
15.
met)
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(1) Send command to open valves


(2) Power supply of steam release valves is not broken
(3) State of program control
(4) Steam release valves are not closed in place
Close of steam release valve (all conditions are
16.
met)
(1) Send command to close velves
(2) Power supply of steam release valves is not broken
(3) State of program control
(4) Steam release valves are not closed in place

Open of emergency water release valves (all


17.
conditions are met)

Emergency water release valves are not opened in


(1)
place
(2) Drum level is high or manually open
(3) Power supply of steam release valves is not broken
(4) State of program control
Close of emergency water release valves (all
18
conditions are met)
Emergency water release valves are not closed in
(1)
place
(2) Send command to close valves
(3) Power supply of steam release valves is not broken
(4) State of program control
Open of steam valves for soot blowing (all
19.
conditions are met)
(1) Send command to open valves
Power supply of steam valves for soot blowing is not
(2)
broken
(3) State of program control
(4) Steam valves for soot blowing are not opened in place
Overheated steam flow is over 70% BMCR and no
(5)
MFT in boiler
Close of steam valves for soot blowing (all
20.
conditions are met)
Send command to close valves or the soot blowing is
(1)
completed.
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Power supply of steam valves for soot blowing is not


(2)
broken
(3) State of program control
(4) Steam valves for soot blowing are not closed in place.
(5) Soot blower does not operate.

8.3 Drying
8.3.1 Purpose
There is moisture in newly-built furnace wall. If putting it into operation directly without slow
drying treatment to increase its strength, the moisture in furnace wall will generate some stress
because of volume expansion caused by sudden evaporation, which may lead to crack,
deformation and damage to furnace wall, even collapse if serious. So, drying under low burning
according to requirements is a must before putting the boiler formally into operation.
8.3.2 Conditions required before drying
(1) Boiler proper and its auxiliary device have been installed, insulated and pass the air
leakage test. The waste inside have been cleared and air leak test of furnance wall is
qualfied.
(2) Main steam pipeline system, water feed system have been installed and pass the
hydraulic pressure test.
(3) Brick laying, heat insulation and finishing of start-up boiler have been completed. Open
every access door to dry the boiler naturally over 72 hours.
(4) Device in drum has been completed. For water level meters, level mark is clear, position
is correct, and illumination is sufficient to read the water level.
(5) Relevant water releasing system have been installed. Water feed pump can feed water to
boiler at any time.
(6) Remote operation of I&C, sound, light and audio signal, and installed and checked
protection device can be put into operation.
(7) Feed demineralized water to the drum water level -30mm, and flush the water level
meter clearly.
(8) Cooling water system has been installed and pass the water test.
(9) Water discharge system has been completed. And discharge is smooth.
(10) Daily oil tank has been installed. Oil tank has been cleared, and oil pipeline has been
blown clearly.
(11) Fuel oil system between oil tank and start-up boiler has been installed, insulated, blown
throughly by compressed air, are with normal hydraulic pressure and ready for oil
supply.
(12) All auxiliary device, valves and dampers of boiler have been tagged.
(13) Each rotatory machine has passed commissioning as a subsystem.
(14) On and off of steam and water valves, flue gas and air dampers of boiler have been
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checked. Their movement is flexible, on-off direction and marks are correct.
(15) Safety protection system of boiler has been tested.
(16) Necessary illumination should be arranged for access road and equipments in
commissioning field. Road is clear; cover on trenches and holes are complete.
Communication is ready for clear liaison.
(17) Steam trap on superheater is on to maintain normal pressure in drying.
(18) Started oil guns of burner on boiler is well atomizedl, burn normally and pass service
test.
(19) The uniform commissioning organization of sufficient number of operators,
maintenance personnel and security personnel shall be built. The operators shall be
trained suitably and be familiar with the associated equipments and systems and
operating methods and aware of commissioning measures, their own responsibilities and
works to prevent incorrect operation.
8.3.3 Methods and Steps
(1) Close manhole of bottom drum, handhole of header, main steam valves, exhaust steam
valves, blow down valves and drain cock of level meter.
(2) Inject demineralized water, with temperature lower than 40℃, into boiler through
economizer to the low water level of boiler (-20—-30mm), and close the water feed
valve. When the water level in boiler is stable, observe whether the level decreases and
check whether water leaks from the cover of the handholes, flange joint and blowdown
valves. If not, bolts should be fastend and maintain low water level in
boiler.(-20—-30mm)
(3) Check whether oil tank has oil, oil pipeline leaks and oil and pipeline heaters are put
into operation.
(4) Start forced draft fans and adjust the damper regulator to blow the furnace.
(5) Ignite with firewood. Control the combustion intensity by outlet flue gas temperature of
furnace. Control the flue gas temperature strictly. On the first day, the rise does not
exceed 50℃. Later, the rise does not exceed 80℃ every day. At last stage, highest
temperature of flue gas does not exceed 160℃. Highest temperature does not last for
over 24 h. During the drying, the water level of boiler should be maintained normal.
Drying period should be controlled according to the degree of natural drying. During the
drying, do not use hard fire, open exhaust steam valve to release air to keep no pressure
in boiler, and heat slowly to avoid blow hot and cold to prevent the insulating layer of
fire proof material from cracking and damage. Keep no pressure rising in drum, steam
pressure for drying is not higher than 0.1MPa.
Note: Installation contractor should make temporary racks inside boiler to keep wood.
8.3.4 Safety Notice for Drying
During the drying, fully open steam trap on superheater and exhaust steam valve at outlet of
superheater.
(1) Flame should be controlled from light to strong and burn in the center uniformly to
ensure uniform exotherm. Check furnace wall and expansion state of each part
frequently, report the abnormal situation timely, if found.
(2) During drying, strictly control the water level in drum, maintain it in normal scope, and
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feed water timely.


(3) Before drying, reserve discharge holes for moisture at proper position.
(4) After drying, prepare temperature rise curve and relevant records.
8.4 Boiling out
8.4.1 Purpose
Eliminate high temperature oxidation peel-roll, corrosion products, welding slag, silt, oil stain
and other debris produced in rolling, processing, storage and installation. Generate protection
layer in the inner wall to prevent corrosion, maintain the heating surface of boiler clean,
increase the steam and water quality to prevent encrustment and corrosion, save fuel, extend
life span and ensure safe and economic operation of boiler unit.
8.4.2 Scope and process of alkaline boil-out
(1) Scope: water screen system, lower drum, upper drum (the part under the flushing
centerline of upper drum )
(2) Washing: three steps are conducted for washing:
‹ Flush with lots of water before washing;
‹ Boil out the boiler with chemicals;
‹ Flush the boiler with hot water after washing.
8.4.3 Conditions required before boiling out
(1) Hydraulic test has been completed and tested.
(2) Commissioning of water feed pumps, induced draft fans and forced draft fans has been
completed.
(3) Chemicals for boiling out and containers for disolution have been prepared.
Commissioning of chemical feed pump has been completed successfully.
(4) Chemical water system can continuously supply enough demineralized water with
sound quality. Flushing and recovery of dosing system have been completed and the
system is ready for operation at any time.
(5) Operator of power generator should be on duty and report state of water quality at any
time.
(6) Temporary indicator lights to indicate high, low and normal water level are equipped at
control room the platform of drum, which have been prepared and accepted.
(7) Operator and installation and maintenance people can operate and prepare necessary
tools. Inspection and preparation for igntion should be done in advance according to
Operation Specification before boil-out so as to make startup and ignition upon
commands.
(8) Systems have been tagged. Correct and clear marks is with various equipments, valves
and flow direction of medium.
8.4.4 The following systems should be commissioned before boiling out.
(1) Flue Gas and Air System:
‹ The inside has been cleared cleanly, checked and accepted.
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‹ Dampers have been adjusted, checked and accepted.


‹ Individual commissioning of forced draft fan has been passed.
(2) Fuel Oil System
‹ Hydraulic pressure test has been passed.
‹ Blowing has been completed;
‹ Fuel oil circulating is qualified;
‹ Fire control device relevant to fuel oil have been tested and accepted.
(3) Water Feed System
‹ 8-hour individual commissioning of water pump has been completed successfully;
‹ Flushing of water feed pipeline has been completed successfully;
‹ Relevant interlock test has been completed successfully.
(4) Dosing system is ready for operation
(5) Industrial water system is ready for operation
(6) Ignition system of boiler
‹ Atomization and service tests have been completed.
‹ Ignition device has been tested normally.
(7) All instruments of boiler have been assembled tested and are ready for operation.
(8) Relevant valves of boiler have been assembled tested and accepted.
(9) Water drainage systems are ready for use.
(10) Water feeding system are ready for use.
(11) Blowdown system of boiler are ready for use.
(12) All other systems that impact ignition of boiler
8.4.5 Method and Procedures
(1) Boiler working and hydraulic pressure test
1) Check that the system meets the requirements for hydraulic pressure test
2) Send water to boiler with water feed pump. In hydraulic test, ambient temperature
should be over 5℃ above zero. Frost protection measures should be taken when
temperature is under 5℃. Temperature of water used for hydraulic test should be over
the ambient dewpoint temperature so as to prevent dew formation on the surface of
boiler. The temperature should not be very high in order to prevent evaporation and high
temperature difference. The temperature is usually within 20℃-70℃.
3) Close the air vent when water comes out from them continuously. Boost pressure slowly
at speed within 0.1—0.15MPa/min. Stop boosting pressure if abnormal situation is
found.
4) Boost pressure to 0.4MPa and fasten bolts of manholes, inspection holes and flanges.
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5) Boosting pressure to 0.98MPa. Stop to check completely whether leakage or abnormal


situation exists.
6) If nothing is abnormal, boost pressure continuously to 1.29MPa and maintain for 20min
to check whether leakage or abnormal situation exists.
7) Hydraulic test is passed if:
‹ No water drops and spray on metal wall or welding.
‹ No residual deformation after the test.
‹ No leakage at connection to economizer.
8) After passing hydraulic test, release pressure and water. During the pressure reduction,
clean I&C tubes, chemical sample tubes and water drainage pipes.
9) Flush boiler with water.
(2) Preparation of chemicals and dosing
1) After the hydraulic test, feed water to 1/3, Stop and check system and isolate the water
feed and drainage and blowdown system. Add chemicals slowly into the container while
agitating. After the chemicals dissolve, feed the solution to the upper drum. Start the
water feed pump of boiler to send water to the low level in drum.
2) Dosing amount: sodium hydroxide (NaOH) 4 kg per m3 water; trisodium phosphate
(Na3PO4) 4 kg per m3 water (calculated according to 100% purity quotient). Water
volume is 22m3 (normal operating water volume in manufacturer's specification)
3) Dosing Requirements:
‹ Before cleaning, feed NaOH or Na3PO4 •12H2O slowly to the container at several
times, and feed demineralized water (or soft water) to dissolve chemicals
sufficiently for future use.
‹ No solid chemicals can be fed directly into the boiler.
4) After feeding chemicals, feed water to flush the container 2 to 3 times.
5) After ignition, supervise water level in drum to maintain normal level. No full water is
allowed. No water comes into superheater.
6) Strictly control burning capacity in the first ignition and pressure boosting. Considering
the expansion in the funnel of furnace wall and temperature difference between upper
and lower wall of drum, pressure boosting rate can not be too fast, increasing to
0.2MPa-0.4MPa within 2 hours. Maintain the pressure and flush water level meter.
Inform the installation contractor to tighten the screws in hot state. Boost the pressure to
0.80MPa within 5 to 6 hours. Maintain pressure at 0.8-1.0MPa for boiling out.
7) Record expansion of each part under the following situation:
Before and after feeding water, 0.4Mpa, 0.8MPa, 1.0MPa. Any part found to impact the
expansion should be reported timely to stop increasing pressure. Continue boosting
pressure after eliminate defect.
8) Start timing when the pressure raises to 0.8MPa. Maintain pressure within 0.8-1.0MPa
for 24 hours in boiling out. Steam drainage volume is 10%-15% of the rated
evaporation.
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9) After 240hour boiling out, maintain pressure of boiler, and each blowdown point
discharge waste and change water. This moment, strictly supervise water level in drum
and prohibit full and lack of water.
10) After feeding chemicals, take furnace water sample by chemical method to test
alkalinity once every two hours. In the later stage of boiling out, test can be done once
every one hour.
11) Normally shut down boiler after boiling out. Decrease pressure and drain water.
12) After the temperature decreases, open the manholes on upper and lower drum and lower
header of water wall to clear away internal foreign matters.
8.4.6 Boiling precautions
(1) Agitate homogeneously when adding chemicals. Must not lift alkaline chemicals on
shoulder or with hands. Operators should ware rubber overshoes, gloves and protection
masks. Cold water resource and relevant chemicals should be arranged in place where
prepare and add chemicals.
(2) No water comes into superheater in boiling out. Strictly supervise the water level in
drums and arrange experienced operators as far as possible to adjust feed water timely.
(3) Closely watch the state of each rotary machine and expansion of boiler proper. Solve
problems timely, if found.
(4) In boiling out, one local level meter is set in drum, and one regulated pressure gauge is
used. Assign people to watch the water level and inform water feeder timely.
(5) Pipeline irrelevant to boiling out should be isolated completely. Prevent washing liquid
in key system from getting into other systems to avoid accident.
(6) In boiling out, blocked blowndown pipeline and valves should be cleared timely, if
found.
(7) In field, road should be clear, illumination should be sufficient, warning sign as
"Washing! Dangerous! " etc. should be pasted, and guard rail and fence should be set.
(8) In washing field, flushing water taps, soaps, towels and emergency medicine (3 L 0.2%
boric solution, vaseline or scream to cure scald) and emergency car should be prepared,
and also take necessary protection measures. If the alkali solution splashes onto skin
or into eyes, flush with fresh water immediately, and then neutralize with 0.2%
boric solution and flush with fresh water again. Ones seriously hurt should be sent
to hospital for rescue immediately.
(9) After boiling out, the manhole can be opened until the temperature of drum wall
decrease to under 50℃ with monitoring of people. When the nuts could be loosen after
2 to 3 threads, use a wooden stick to unclench door of manhole (No people face the door
directly). After the inside negative pressure disappears, open the door of manhole and
assemble reticular close board on it.
(10) If no measures are mentioned for some conditions, execute the "Boiler Operation
Specification". If accident occurs, deal with it according to Specification for Accident
Handling.
8.5 Steam Purging
8.5.1 Purpose
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Commissioning
Procedure
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To ensure the safety and economy operation of the units, the inevitable welding slag, metal
rust and other sundries in the boiler superheater and pipeline of steam system of newly
assembled units shall be purged to the cleanest extent before the formal steam supply.

8.5.2 Scope
‹ Boiler superheater system

‹ Steam pipeline connecting start-up boiler to auxiliary steam header


8.5.3 Purging plan
‹ Purge the boiler superheater system by energy storage (pressure decrease) method.
‹ the Process: steam drum--> superheater--> main steam valve--> main steam pipeline-->
temporary vent pipeline
‹ Purge steam pipeline connecting start-up boiler to auxiliary steam header and boiler
superheater system simultaneously.
8.5.4 Steam parameter for purging
Open main steam valve when the drum pressure reached 0.5~0.6MPa. After fully open main
control valve, drum pressure decreases to 0.4~0.5MPa. At that time, close main steam valve.
8.5.5 Quality standard
According to the new "Technical Code for Erection and Acceptance of Electric Power
Construction (1996 Edition)", while ensuring the purging factor larger than one, the purging
work is qualified as the matter, maximum particle diameter on the target board no more than
0.8mm and number of macroscopic spot no more than 8, happens for twice continuously.
8.5.6 Temporary devices
(1) The temporary pipeline shall be connected in proper place before plant-service steam
header and be led to safe place for steam exhausting with outlet directed to open space.
Target board shall be installed in the suitable place near regular pipeline. In condition
that the quality of purging is guaranteed, minimize the length of the pipe, elbows and
joints to reduce the resistance for the system.
(2) Temporary purging pipeline shall be equipped with solid and reliable supports and
hangers and consider the thermal expansion of the pipeline and steam counterforce by
purging.
(3) Same-diameter short pipe shall be connected instead of main steam flow orifice plate
until the purging work is finished.
8.5.7 Precondition for ignition
(1) Systems return to normal after boiling and cleanup of upper and lower drum and
sub-header of water wall.
(2) Main boiler and auxiliary equipments have been installed and insulated. Plateform,
handrail and boarding are complete.
(3) All facilities which affect the expansion have been removed.
(4) Sufficient illumination is around the boiler proper and auxiliary units.
(5) Installation of water level meter in drum shall meet the requirements. The local water
level meters are accurate and remote water level meters are regulated and can be put into
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
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use for purging.


(6) Sundries shall be cleared up inside the furnace and funnel.
(7) Water charging and supply system shall meet the requirement and be ready to use.
(8) Purging control valve have been adjusted and temporary pipeline have been completed
according to requirement.
(9) In boiler house, discharge systems of washing water and overflow have been installed as
per design requirements.
(10) Dosing, sampling, blowdown systems have been installed as per design requirements.
(11) Chemical water treatment system can guarantee to supply qualified demineralized water.
(12) Purging field is tidy, road is clear, trench covers are complete, and scaffolding have been
removed for convenient operation. Operating floor has been completed basically without
any vulnerability such as voids etc.
(13) The utilities system can guarantee the safety and stability of production, construction
and commissioning.
(14) Preparation work has been done for commissioning. Operators, trained and tested, are
qualified. Operation specifications and system diagram have been approved. Operating
tools are fully equipped and commissioning log is prepared.
(15) A sound commissioning management organization has been established, the
responsibilities and liaison system have been clearly defined. Personnel for adjustment,
maintenance and operation are on board. Commissioning measures have been approved
and technical clarification has been performed.
(16) Chemicals materials, chemical water and fuel oil for commissioning are ready.
(17) Fire-fighting equipments and facilities in field shall meet the requirements.
(18) The Installation Contractor, Operation Contractor, Owner, Supervisor, Contractor and
Commissioning Contractor inspect the entire units thoroughly to confirm that the unit is
ready for ignition. Problem found must be solved immediately, if any.
8.5.8 Tests before ignition
(1) The system valves and dampers for purging shall be inspected completely by operators
to meet the following requirements: flexible operation; on-off direction accords with the
indication; and remote panel conforms with local one.
(2) Test for interlock protection
8.5.9 Preparation before ignition
(1) Start up water feed pump until the water level reaches about -30mm in the drum.
(2) Preparation before ignition should been made as per specifications when receiving
ignition signal.
‹ Notify the electric control room to feed the rotary machine, electric dampers and
electrically operated steam and water valves to be used.
‹ Heating control room feeds the panels and instruments to be used.
‹ Put cooling water system into use.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
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‹ Ignition is implemented as per specifications.


8.5.10 Purging process
(1) Ignite and increase the pressure once receiving ignition signal. When the pressure
reaches to 0.2MPa, steam pipeline should be warmed up. After that, trial purging is
started and check if the system expansion and stress state are normal when the pressure
is up to 0.3MPa. If normal, boost pressure continuously to 0.4MPa~0.5MPa for next
purging until the target board is basically qualified. Then shut down and cool the boiler
for 12hr and ignite the boiler and boost the pressure again to purge until the target board
is qualified.
(2) After purging, to boost pressure for leak test and safety valves adjustment or to shut
down for system recovery is subject to the site conditions.
8.5.11 Safety precaution and instruction
(1) Keep combustion as stable as possible when purging.
(2) The drum water level control to avoid severe water shortage or overfall is of the greatest
significance during purging period.
As the control valve opens, the steam pressure decreases sharply, which causes great rise
of drum water level. Actually, it is false appearance, and the water supply shall be
increased suitably rather than being decreased. For the reason that the drum water level
declines greatly even it is invisible when the control valve is closed, increase the water
supply to maintain a visible level when closing the valve. When the water level starts to
rise again, reduce the water supply promptly to avoid rising too high.
To prevent steam from bearing lots of water, the drum water level shall be maintained
around -50mm before opening the control valve in purging.
(3) No flammable and explosive materials near purging pipeline. No people in area 20m
around steam outlet. Set guard line and assign persons to be on duty.
(4) Make sure that everyone has left before opening the control valve, especially when
changing the target board. Person unrelated shall keep away from purging pipeline
(5) Pipeline shall be warmed up completely before purging. Trial purging, under the
pressure 50%~75% of the regular pressure shall be conducted once or twice to inspect
the conditions of support, expansion and leakage of the temporary system and learn the
control method of water feed flow gradually. Steam trap on main steam pipeline shall be
partially opened while the other is closed during normal purging work.
(6) A target board shall be put in the pipeline to check the dirtiness of pipeline and the
reliability of board in the first purging.
(7) All rotary machines shall be monitored by relevant personnel.
(8) Operation should be conducted in a manner of unity of command. Shut down purging in
case of emergency, and handle accident according to Accident Management Procedure.
(9) The parts unable to be purged by steam shall be cleaned mechanically and manually.
Safety measures shall be considered to prevent the dirt from recovered welding joint.
(10) 20 pieces of target board, made of aluminum and polished, should be prepared.
Target boar size: no less than 8% of the inner diameter of discharging pipeline in width;
and equal to the inner diameter in length.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
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8.6 Steam Tightness Test


8.6.1 Purpose:
To guarantee the safety operation of the units in future, the steam tightness test, under the
operating pressure at hot state, is to completely inspect the boiler's heating surface, the steam
& water pipeline, steam header, flanges. welded junction, expansion system and load-carrying
capability, displacement and the extension of fixing apparatus or spring supports and hangers.
8.6.2 Test Content:
(1) Close the main motorized steam valve at the boiler outlet; the pressure boosting rate can
be controlled by the adjustment of fuel oil pressure or the exhaust steam valve. When
pressure rises to 1.29MPa and is at steady state, people specially assigned shall check
the tightness of the boiler proper, auxiliary device and the steam and water pipelines
involved.
(2) Inspection the tightness of welded joints and flanges of the boiler.
(3) Inspection tightness of all the steam and water valves of the boiler proper system.
(4) For steam and water pipeline of the boiler, check its expansion condition, check whether
the load-carrying capability, the displacement and the extension of its supports, hangers
and spring hangers are normal, and check whether any barriers impact the expansion.
8.6.3 Testing conditions:
(1) Purging has been completed.
(2) Areas inside and outside boiler is cleaned. Road is clear.
(3) No expansion barriers on boiler proper. Expansion indicator has been installed and
regulated to zero.
(4) All inspection holes and manholes have been closed.
(5) Tests and inspections before ignition have been completed.
8.6.4 Test Procedure:
(1) Timely adjust combustion intensity and open rate of steam trap. Control temperature and
pressure rise rate according to Operation Specification.
(2) Record expansion value at the following conditions: before and after water feed,
0.3–0.4Mpa, 1.0MPa, 1.29MPa.
(3) Start steam tightness test when pressure of main steam rise to 1.29MPa.
8.6.5 Safety Precautions:
(1) Strictly control increasing rate of temperature and pressure to ensure sufficient
expansion of each heating part of boiler proper.
(2) Check the expansion state of each heated part in pressure boosting process. Report
problems if found. Stop increasing temperature and pressure, if necessary, to take
measures to eliminate a hidden danger. Then continue the process.
(3) Operation should be conducted in a manner of unity of command. Strictly follow orders
and prevent personal injury and damage to equipment. All operating personnel
participating commissioning shall strictly follow Safety Regulations and related safety
provisions at site, thus to ensure safe and reliable commissioning.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler REV A
Commissioning
Procedure
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(4) If equipment damage or personal injury may occur, stop works immediately and shut
down the unit if necessary, and then analyze causes and take corrective measures;
(5) During entire commissioning, personnel of various discplines shall be in place, thus to
ensure equipment operation safety.
8.7 Safety valve setting
8.7.1 Purpose:
Being the primary safety devices for the boiler, safety valves of drum and superheater shall be
adjusted to act accurately and reliably before commissioning to ensure the safe operation of
the boiler unit.

8.7.2 Setting parameter: Refer to attached table.


8.7.3 Preparation before tests
(1) Safety valves have been installed and checked, which accords with installation
requirements.
(2) Standard pressure gauges, provided by the installation contractor to adjust the safety
valves, have been installed (0~5MPa per one, above grade 0.5).
(3) Safety valves platform is clean. Road is clear. Illumination is sufficient.
(4) Adjustment tools, communication tools and record lists are prepared.
8.7.4 Setting procedure
(1) Start steam discharge test when pressure rise to 0.8MPa-0.9MPa. Check the steam
discharge and action of safety valves. If no problems found, continue boosting pressure
to the setting pressure needed for setting. The setting of safety valves is conducted
before the setting of safety valve of superheater.
(2) Decrease pressure after the setting of safety valves. Start the setting of safety valves on
the superheater.
(3) If the trial actuation of the safety valve is not qualified for the first time, decrease
pressure and adjust it again. Then increase pressure to test the trial actuation until it is
qualified.
8.7.5 Safety Precautions:
(1) During the adjustment of safety valve, operators and safety valve adjustors should act
according to the unified command of commissioning personnel so as to ensure personal
and equipment safety. .
(2) Participants should keep their post according to work division and take records of
operation, adjustment and check.
(3) During the adjustment, enough platform and railings should be set around safety valves;
illumination is sufficient.
(4) Before setting, release the drum water level protection, in case the false level caused by
take-off of safety valve starts the protective action of boiler.
(5) During pressure boosting, assign people to check the tightness and expansion of boiler.
Report and solve problems found to impact the increasing of pressure and temperature
timely.
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Procedure of Start-up Boiler REV A
Commissioning
Procedure
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(6) During the adjustment, operator is responsible to maintain the stable working state of
unit, especially the stable pressure. At the moment the safety valves discharge steam,
drum water level changes greatly. So, when adjusting the safety valves, drum water
level should be lower than the normal level. Adjust the water supply to control the drum
water level properly.
(7) Decrease the pressure to 75% of the actuation pressure before adjusting the safety valves.
Experienced operator with protection masks and heating-insulated gloves adjust the
safety valves, and others should be kept away from the field.
(8) During the adjustment, adjust the weight of safety valves on drums. Remove top cover
of safety valves on superheater, unscrew or wind up spring to reach the set actuation
pressure. Then tighten fastening screw, assemble the top cover and tighten the hexagon
screw.
(9) Do not hit any parts on the safety valve. Lift handle directly to open the safety valve.
(10) After the adjustment of safety valve, all externally adjusted parts should be marked,
fastened, sealed, recorded and certificated before put into operation.
Attached List:
Design value Actual setting value
Name/Type Popping Return Pressure Popping Pressure Return Pressure Remarks
Pressure(MPa) (MPa) (MPa) (MPa)
Drum
Safety valve 1.43 1.33-1.37 4-7%
A48Y-25
Super heater
Safety valve 1.30 1.21-1.25 4-7%
SA48Y-25
Remarks: Actuation value of safety valve is from the Manufacturer's Information.
8.8 Load commissioning
8.8.1 Test purpose:
Load commissioning is main process of unit commissioning. Concerning to the safety, quality
and project period of unit commissioning, load commissioning is a comprehensive
performance evaluation of the unit and complete check and inspection of the sub-system
commissioning at the early stage.
8.8.2 Conditions required before load commissioning
(1) Drying and boiling out, steam purging, tightness test, safety valve setting of start-up
boiler have been completed.
(2) All temporary system used in sub system have been removed.
(3) All defects found in the subsystem commissioning have been eliminated.
(4) Chemical water system is complete to supply qualified demineralized water at any time.
(5) Plant-service power system is complete to cut and supply power according to
commissioning requirements at any time.
(6) Illumination and communication system is complete to communicate at any time. Fire
control equipments are equipped.
PLTU 1 Jatim-Pacitan(2×315MW) Project
Procedure of Start-up Boiler