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Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 1 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) SLNO LIST OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES a) LOG SHEET b) CHECKING AND COMMISSIONING OF VFD.

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 2 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO 1.0 PLANT DETAILS: The plant details of the Draft System is as follows. 1.1 Induced Draft Fan No of Fan Type Make Flow Pressure Temperature Drive Speed Motor Rating Control 1.2 Forced Draft Fan No. of Fan Type : 2 : Axial AP 1-26/16 Axial Reaction, single stage with silencer. : 2 : NDZV 47 : BHEL : 558.2 cu.m/Sec : 485 mmwc : 1530C : Motor : 580 RPM : 3650 : Inlet Damper plus variable Frequency Drive. (VFD).

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 3 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO Make Flow Pressure Temperature Drive Speed Motor Rating Control : BHEL : 246 cu.m/Sec : 351 mmwc : 500C : Motor : 980 RPM : 1175 KW : Variable Blade Pitch control.

The boiler is also equipped with primary air fan, which form a part of the coal preparation and firing system. 1.3 Primary Air Fan No. of Fan Type : 2 : Axial AP 2-20/12 Axial Reaction, Double stage with silencer : BHEL : 170.5 cu.m/Sec : 1183 mmwc

Make Flow Pressure Signatures NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 4 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO Temperature Drive Speed Motor Rating Control 1.4 : 500C : Motor : 1480 RPM : 2450 KW. : Variable Blade Pitch control.

All the fan are mounted on concrete deck with suction and discharge duct. Connected to the Fan flanges. FD Fans and PA fans are provided with Silencer at the suction duct. Regulation of Fan from no load to full load is performed by changing the pitch angle of blade profile on all blades simultaneously during operation. This is achieved through a sophisticated servo mechanism (Hydraulic Servo Motor0 externally actuated by a power cylinder or Servomotor and forced lub-oil system. In the case of ID Fan, the equipment is driven by variable frequency drive motor coupled with soft coupling. The regulation of the fan is effected through the inlet dampers located at the inlet of the fan and variable speed by VFD. In FD and PA fans, the rotor is supported in antifriction bearings and cooled by forced lubricating oil. A thrust bearing is provided to absorb axial loads. Thermometers are provided in the bearing housing for temperature monitoring. In ID Fan, the bearings are while metal sleeve type with forced oil lubrication. Fixed bearing near drive end is designed to absorb the Axial forces. Thermometers are provided in the bearing housing for temperature monitoring.

1.5

1.6

1.7

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 5 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO 1.8 1.9 1.10 Respective O & M manuals to be referred for typical drawing of each fan. List of plant Item readiness (Mechanical, Electrical and C&I) are to be prepared at site before commissioning of the fans. Safety Rules clearance certificate to be signed at site before commissioning of the fans. OBJECTIVE: To commission the fans (ID Fan, FD Fan and PA fan) and make it available for commissioning and operation of the Unit. 3.0 PROPOSAL It is proposed to commission the fans as per the following proposals. 3.1 3.2 3.3 4.0 4.1 4.2 Signatures NTPC BHEL Oil flushing of lub-oil system (Refer to Testing schedule BHEL Ref.No PS-DC-186-500-0013A/SIM/1/TS/1/003A) Trial run of H.T. Motor for 8 Hrs. Trial run of Fan for 8 Hrs. SERVICES REQUIRED Availability of O & M Manual for fans Availability of auxiliary cooling water

2.0

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

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Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO 4.3 4.4 4.5 4.6 Availability of L.T/H.T. Power supply Availability of lighting, communication facility at the test area. Availability of portable fire extinguishers Availability of working crew with Technician for attending minor problem during commissioning of Fans. SAFETY PRECAUTIONS: Availability of first aid kit at test area. The team commissioning the fan should be aware of the procedure adopted. Agencies working in the boiler area / associated ducting system are informed about the test / cleared from the test area (As per the actual requirement). All loose materials around the fan area are cleared. Required approach stair cases, platforms and hand rails are erected prior to testing. Oil collecting trays and sand buckets are made available at test area.

5.0 5.1 5.2 5.3

5.4 5.5 5.6

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 7 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO 6.0 6.1 6.2 6.3 EMERGENCY PRECAUTIONS: The group conducting the test should be aware of action to be taken on the event of injury to personnel. The group shall be aware of operating instruction of portable fire extinguishers. The test team should be aware of the steps to be taken to trip the running equipment in case any emergency / abnormal observations are notified to them.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 8 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO 7.0 7.1 STATE OF THE PLANT Erection of the following are completed. Lub oil system All the lub oil control oil pipe lines C.W lines Fan and its H.T.Motor Suction and discharge duct and their connection with fan. L.T./H.T switch gears required for the fan. 7.2 7.3 7.4 Fan casing, Suction / Discharge ducts are cleared off men & temporary materials. All permanent supports and guides of fan & duct are erected. All local instrumentation of lub-oil system, motor and fan are erected. (Required list to be prepared at site) )Pressure and temperature indicators are duly calibrated) Remote indication at control room are made available (List to be prepared at site) Recommended lubrication oil is filled up in the lubrication system.

7.5 7.6

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 9 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO 7.7 Blade pitch operation (for FD & PA fan) and inlet damper operation for ID fan) verified at local and the same ensured from remote for correct opening / closing with respect to position indicator at local and remote. Free movement of Blades & inlet dampers are ensured. ACW lines are flushed and connected to the respective inlet points. ACW inlet / outlet connections to ID fan sleeve bearings are connected as per the indicated markings. Ensure variable frequency Drive (VFD) system is made ready (In case of ID Fan for operation of the Fan. (Refer to the procedure enclosed in Section 10.0.) Insulation resistance of the motor measured and ensured that the values are at satisfactory level.

7.8 7.9 7.10

7.11

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 10 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO 8.0 8.1 METHOD Start lub-oil system and establish oil circulation at recommended oil pressures (Both lub-oil and control oil, which ever is applicable) After obtaining clearance from all agencies, start the motor in decoupled condition and check the direction of rotation. If direction found reverse, change the direction of rotation of the motor. Refer to section 10.0 for details regarding checking and commissioning of VFD system. In addition commissioning manual of VFD issued by supplier to be followed in the commissioning of VFD system. Start the motor once again and put under 8 Hrs trial run (FD and PA motors). In the case of VFD synchronous Machine, put the machine under 4 Hrs trial through channel I and under 4 Hrs trial through channel II. Performance of the motor to be monitored by logging load current, vibration and temperatures of bearings and windings, whichever applicable. After satisfactory completion of drive trial run, drive and the fan are coupled. Start the fan and put under 8 Hrs trial run.

8.2

8.3

8.4

8.5

8.6 8.7

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 11 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO 8.8 Blade pitch for FD and PA fan to be at minimum before starting the fan and after starting, fan to be slowly loaded up to around 10-15% (Exact loading of the fan to be decided at site) For ID Fan, keeping the inlet damper at minimum, Fan started and loading to be gradually increased to 10-15% (Exact loading of the fan to be decided at site) During 8 Hrs trial run, Fan performance observed by logging load current, vibration, temperatures of the bearings, parameters of lub-oil system VFD system and draft values in PA,SA and Gas circuits covered in single fan running condition.

8.9

8.10

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0033 NTPC Ref no SIM/1/TS/1/33

Sheet 12 of 15

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN) STATUS SL.NO 9.0 COMPLETION CRITERIA Commissioning of Fan (ID Fan, FD fan and PA Fan) completed with satisfactory completion of a) Oil flushing of Lub-Oil system b) Trial run of motors for 8 Hrs c) Trial run of Fan for 8 Hrs. (8 Hrs trial each for motor and Fan of FD and PA system and 8 Hrs trial for motor and Fan of ID system with channels I ans II each inservice for 4 Hrs duration) 10.0 APPENDICES: a) Log Sheets. b) Checking and Commissioning of VFD

Signatures NTPC BHEL

PROCEDURE FOR COMMISSIONING OF FANS (ID FAN, FD FAN AND PA FAN)

SHEET 13 OF 15 10.0 Project : Unit : Activity : LOG SHEET DATE :

LUB-OIL SYSTEM SL No TIME Discharge Pressure Filter DP Control Lub-Oil oil Pressure pressure Oil Temp after cooler Tank Oil Level

BEARING TEMPERATURE Motor DE NDE DE Fan NDE Draft (Suction/ Discharge) Remarks

Signatures NTPC BHEL