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Commissioning Measures Form for Approval

No.YDTD-TS09

Project name

Phase I of 2330MW Project of Tengda Contract Coal-fired Power Plant in India


No.

To: Tengda Project Department of Sichuan Machinery & Equipment Import & Export Corporation
Now it is submitted for the examination and approval with the rubber ball cleaning system commissioning measure Document No. : QJCS-9 Appendix: rubber ball cleaning system commissioning measure

Contractor: Sichuan Tongneng Power Technology Co. Ltd.

Project principal

Date

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

Examination and approval opinions of the project supervision department:

Project supervision department (seal)

Supervision engineer:

Date

Chief supervision engineer:

Date

Examination and approval opinions of the owner

Legal person of the project (seal):

Owner representative

Date

Contractor: Sichuan Tongneng Power Technology Co. Ltd

Mar. 2008

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India

Rubber ball cleaning system commissioning measure

Sichuan Power Industry Commissioning Test Institute Sichuan Tongneng Power Technology Co., Ltd
Mar. 2008

Examination and Approval Record for Documents


Document name Document No. The 1st version Date publication Date The 2nd version Edition no. Date publication The 3rd version of Main revised content publication of Main revised content of YDTD-QJCS-09
rubber ball cleaning system commissioning measure

M a n a g e r s approval of the commissioni ng project Date:

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

Review of the principal of professional group of Date: commissioni ng project

Compiler of the technical document Date

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

Content
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Compilation purpose Compilation reference Quality standards and objective of commissioning Responsibility division System brief introduction Conditions prior to commissioning Working procedure of commissioning Commissioning steps Safety Precautions Appendix 3 3 3 4 5 6 6 6 11 13

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

1. Compilation purpose
1.1 These measures are worked out for guiding and standardizing the commissioning work of system and equipment, and ensuring that the system and equipment can be used safely and normally. 1.2 Check electric, thermal protection interlock and signal devices of rubber ball cleaning system to confirm that they can run reliably. 1.3 Check the operation situation of the system and equipments and performance of the system to find and eliminate the possible defects.

2. Compilation reference
2.1 Specifications for Start-up and As-built Acceptance of Capital Construction Engineering of Thermal Power Plant (1996 Edition) DJ[1996] No. 159) 2.2 The Codes of Erection and Acceptance of Electric Power Construction (Section of Steam Turbine Unit) DL50111992 2.3 The Codes of Erection and Acceptance of Electric Power Construction (Section of) DL50311994 2.4 Standard for Quality Inspection and Evaluation of Thermal Power Engineering Adjustment and Commissioning (JZ [1996] No.111) 2.5 Regulations for Start-up and Commissioning of Thermal Power Engineering (JZ [1996] No.40) 2.6 Drawings, Installation and Operation Instructions, Warranty and Certificate of Merchandise of manufacturer 2.7 Design documents, drawings and instructions, related documents, meeting minutes, etc. of commissioning 2.8 Equipment supply agreement and international and national standards specified in the supply agreement.

3. Quality standards and objective of commissioning


3.1 The commissioning should be in accordance with all quality standards and requirements of relevant rubber ball cleaning system and equipments specified in the Standard for Quality

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

Inspection

and

Evaluation

of

Thermal

Power

Engineering

Adjustment

and

Commissioning (1996 Edition), and the quality requirements specified in commissioning contract, and satisfy the requirements of complete set start-up of unit. 3.2 The professional commissioning personnel and group leader should inspect and control the key links of commissioning quality according to Appendix 1 (Quality Control Point of Commissioning). For the problems found during commissioning, they should report to the superiors in time so as to solve them and ensure that the start-up commissioning work can go on smoothly.

4. Responsibility division
According to related provisions specified in the Regulations for Start-up and Commissioning of Thermal Power Engineering and commissiong contract, the duty of each party is as follows: 4.1 Installation unit: 4.1.1 Be responsible for the commissioning and trial run works of individual sectors of the equipment. 4.1.2 Be responsible for insulation work of the system. 4.1.3 Be responsible for the examination, repairing, maintenance and defects eliminating works of the commissioning equipments. 4.1.4 Prepare necessary examination and repairing tools and materials. 4.1.5 Coordinate with commissioning unit to carry out the commissioning work of sub-systems. 4.1.6 Be responsible for the certificate issuing works after commissioning of this system in divided parts. 4.2 Manufacturing unit: 4.2.1 Be responsible for the starting and stopping of equipments, operation adjustment and failure handling during commissioning. 4.2.2 Be responsible for the formal label-hung works of the related system and equipments. 4.2.3 Prepare the operation regulations, tools, record forms, etc. 4.2.4 Be responsible for the inspection and normal maintenance works of equipments during commissioning. 4.3 Commissioning unit: 4.3.1 Be responsible for the compilation works of commissioning measures (scheme) and

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

confide technical disclosure. 4.3.2 Prepare related instruments, meters and tools used in the test. 4.3.3 Be responsible for commanding works on commissioning of sub-systems. 4.3.4 Be responsible for the recording and analyzing works of testing data. 4.3.5 Fill in the commissioning quality inspection and evaluation table 4.3.6 Be responsible for the acceptance and certificate issuing works of sub-systems after commissioning. 4.3.7 Write commissioning reports. 4.4 The installation unit is responsible for while the commissioning unit participates in the commissioning works of individual sector of pump sets. The commissioning unit is responsible for the sub-system commissioning of the pump sets coordination with installation unit and other related units. The commissioning of rubber ball cleaning system should be carried out under the unified command of trial run team and implemented under the duty of the professional team, coordinating with leads in turbine profession, electric, thermal control and other related professions.

5. System brief introduction


The both sides of turbine condenser of Tengd a Coal-fired po wer plant in Ind ia have one set rubber ball cleaning device which is constituted of ball collecting screen, rubber ball pump, ball loading chamber and other components. Passing through rubber ball pump, the rubber ball is brought out from ball loading chamber by the circulation water, and then runs into the inlet circulation water of A condenser, and runs to rubber ball pump from circulation water by the ball collecting screen on outlet circulation water pipe of B condenser at last, repeatedly circulating like this. Specification of equipments 5.1 Rubber ball pump: Type: WX-JQ-100 Flow: 100m3/h (27.8L/s) Head: 25m Shaft power: 10.4KW Net positive suction head: 1.6m Speed: 1460r/min Efficiency: 60% 5.2 Motor Manufacturer: ABB MOTORS
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

Type: QA162301-ADA Power: 11KW

6. Conditions prior to commissioning


Before system commissioning, the commissioning personnel should have a comprehensive examination on the requirements for this system commissioning in accordance with the contents listed in Appendix 2 (Checklist for requirements of commissioning), and keep a record.

7. Working procedure of commissioning


The commissing work of rubber ball cleaning system can be carried out in accordance with the following flow: Technical disclosure of commissioningconditions needed to be confirmed before commissioninginterlock protection and alarm testsqualified trial run of rubber ball pumpuse of system and dynamic adjustment

8. Commissioning steps
8.1 Inspection on actuator 8.1.1 Check and accept the electric switching throttle, and record the following data: a. KKS code b. Name (if the power plant has specific description on throttle, then take this description as standard) c. The indication of the on-the-spot position is correct or not d. The operation direction on the electric panel and the feedback are correct or not e. The operation direction on the computer and the feedback are correct or not f. Open/Close time of the valve 8.1.2 Check and accept the ball collecting screen , and record the following data: a. KKS code b. Name (if the power plant has specific description on throttle, then take this description as standard) c. The indication of the on-the-spot position is correct or not d. The operation direction on the electric panel and the feedback are correct or not

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

e.

Open/Close time

8.2 Trial run of rubber ball pump 8.2.1 The idle run test of motor of rubber ball pump 8.2.1.1 8.2.1.2 8.2.1.3 Confirm that the installation work of motor is over. Confirm that the driving power of motor is off, the motor insulation is qualified Confirm that coupling between motor and primary air fan has been uncoupled, fill the bearing of motor with needed lubricant. 8.2.1.4 Rotate the motor rotor, confirm that dynamic and static parts have no friction and bearing has no abnormal sound; 8.2.1.5 Confirm that program controlling test of motor of rubber ball pump is qualified. Switch on the driving power and operation power of motor. Start up the motor on MCC panel, do not press emergency button to stop motor on the spot until the motor current falls back, notice that there is abnormal sound or not in rotation, and record the following data: a. Voltage b. Start-up current 8.2.2.3 The rotation direction of motor should conform to the specified requirements of manufacturer and design. 8.2.3 Trial run of the motor 8.2.3.1 After 20 minutes, restart the motor on MCC panel. Notice that the start-up time intervals do not less than that required by manufacturer or electric regulations, the rotation has no abnormal sound or not, and record the following data: a. Start-up current b. Current in motion c. Bearing vibration d. Bearing temperature 8.2.3.2 8.2.3.3 After 4-hour trial run, stop the motor on MCC panel and record the end time. Switch off the driving power of motor. Check and confirm that the following conditions can be satisfied before trial run: 8.2.2 Inching of motor 8.2.2.1 8.2.2.2

8.2.4 Trial run of rubber ball pump 8.2.4.1 a. Confirm that each device, pipelines, electric connections, etc. conform to the

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

requirements. b. Wash the inlet pipelines of rubber ball pump by circulation water in trial run, and reconnect the pipelines after washing. c. The trial run of individual sector of rubber ball pump motor is over, and the coupling of motor and rubber ball pump are restored normal; d. Confirm that the rubber ball cleaning system have been installed and the system is complete; e. Put the meters of system into use; f. The valve state of pipeline of rubber ball pump conforms to the requirements of trial run. g. Each bearing of rubber ball pump has sufficient lubricant and cooling water. h. Check that the compression of stuffing should not be too tight and loose, and the stuffing gland should be compressed even. i. Manually rotate the rotor of rubber ball pump, and the results indicate that the rotation is normal. j. The insulation resistance of motor of electric valve has been measured, and conforms to the requirements. The power has been switched on 8.2.4.2 Confirm the following start-up condition for the last time: a. The oil level of bearing is normal; b. Confirm that the water level of circulation water basin is normal and the circulating pump has been started; c. Close all drain valves of pump sets, ball loading chamber and pipes; d. Open the outlet valve of rubber ball pump, fill ball loading chamber with water and do not close the extraction valve of ball loading chamber until it was filled with water. Close the outlet valve of rubber ball pump when finishing the water injection. 8.2.4.3 Switch on the driving power of the pump, and stop it for checking following items after starting for 5 seconds: e. The rotation direction of the pump conforms to the design requirements or not f. Have abnormal sound or not g. The oil level and temperature of bearing is normal; the oil temperature is normal and not higher than the fixed value specified by the manufacturer. The used lubricating oil is 65 70, and the grease should not exceed 80
h. Check the vibration is normal or not; the vertical, horizontal and axial vibration of bearing measured by qualified vibrometer should not exceed the following specifications in the situation of no load and
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

full loads. Vibration amplitude (mm) Excellent 0.04 Good 0.06 Qualified 0.08

i. Check that the water pipes of the system have leakage or not 8.2.4.4 If have no abnormal phenomenon, restart the pump, open the outlet valves of rubber ball pump and ball loading chamber, and then record the following parameters: a. Start-up time b. Start-up current c. Current in motion d. Bearing temperature e. Vibration f. Inlet pressure g. Outlet pressure 8.2.4.5 8.2.4.6 Check the system has leakage or not. The rubber ball pump keeps 8-hour trial run. After trial run, stop it and record its end time and idle time. 8.2.4.7 Switch off the driving power of rubber ball pump. 8.3 The use of rubber ball cleaning system 8.3.1 The conditions before use 8.3.1.1 8.3.1.2 8.3.1.3 8.3.1.4 8.3.1.5 The circulation water system works normally. The ball collecting screen has been placed at the position of operation. Rotate the rotor of rubber ball pump, confirm that it is flexible without friction. Check that the inlet and outlet valve of rubber ball pump can be closed normally. Put the desired rubber balls into rubber ball chamber, place the changeover valve at washing position, close the drain valve and fully open the extraction valve. The rubber balls should meet the following requirements: a. The rubber ball should be wear-resistant, soft and elastic with same-sized and through holes, the specific gravity in wet state is 1.01.15.During the period of use, the diameter of the rubber ball swells in standard scope without aging in the 545 water. b. The diameter of rubber ball in wet state is 1.02.0mm bigger than internal diameter of comparatively small cooling pipe.

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

c.

The used rubber balls should be 7%13% cooling pipe of single flow of condenser in normal operation. Put in 200 rubber balls at each side when doing the test of ball recovery rate.

d. Immerse the rubber balls in water for 24 hours before use. 8.3.1.6 8.3.1.7 8.3.1.8 Do not switch on the power until the insulation of motor side of rubber ball pump is qualified. Check that the power of Programmable Logic Controller (PLC) has been switched on or not and the indicator light of simulation display screen is normal or not. This cleaning device is automatically controlled by Programmable Logic Controller (PLC), the modification of program can change the automatic cleaning time. 8.3.2 The use of rubber ball cleaning device (Automatically start up and confirm the following items by PLC) 8.3.2.1 8.3.2.2 Switch on the rubber ball cleaning system. Open the outlet valve of rubber ball pump, fill ball loading chamber with water and do not close the extraction valve of ball loading chamber until it was filled with water. Close the outlet valve of rubber ball pump when finishing the water injection. 8.3.2.3 Open the rubber ball pump and check that the rubber ball pump works normally or not. 8.3.2.4 8.3.2.5 Open the outlet valve of rubber ball pump and ball loading chamber. Monitor the operating situation of rubber ball by transparent window, check it to be normal if there are rubber balls constantly returning after several minutes, about 30 min for one time cleaning. 8.3.2.6 8.3.3 Do the check test of ball recovery rate of rubber balls: Check the percentage that returned rubber balls relative to the used rubber balls after finishing the cleaning. The stop of rubber ball cleaning device (Automatically start up and confirm the following items by PLC) 8.3.3.1 Place the changeover valve at ball collecting position after cleaning, and collect balls for 30min. 8.3.3.2 Close the outlet valve of rubber ball pump, stop the rubber ball pump and close the inlet valve of rubber ball pump. 8.3.3.3 8.3.3.4 Close the outlet valve of ball loading chamber. Open the extraction valve and drain valve of ball loading chamber, check the amount of rubber balls and record the ball recovery rate, cleaning time, etc. after draining the
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

water. 8.3.4 Dynamic adjustment of the system During the operation of rubber ball cleaning system, strengthen the supervision of each device in the system, and adjust any abnormal situation immediately, so as to guarantee the system reach its best operation. a. Pressure adjustment b. Temperature adjustment c. Current adjustment 8.3.5 Fill in the trial run record The main parameters in trial run should be recorded in Appendix5.

9. Safety Precautions
9.1 All personnel participated in the commissioning should strictly implement the Codes for Safety Operation and related safety regulations on job site so as to ensure the commissioning work can go on safely and reliably. 9.2 The commissioning works should be stopped immediately if person or equipment is possibly endangered or has been endangered during commissioning. Find out and analyze the reasons, and then submit the solutions. 9.3 The abnormal conditions found during the process of commissioning should be adjusted in time and reported to the commanding personnel immediately. 9.4 The professional personnel of each field should be on guard during the whole process of commissioning so as to ensure the operation safety of equipments. 9.5 If the operating pump in vaporization, equipment or pipes occur strong vibration and parameters of current and bearing temperature and so on are obviously super-standard, etc., the commissioning personnel should immediately stop the heater and commissioning, find out and analyze the reasons, and then submit the solutions. 9.6 Do carefully check the oil level of bearing to be normal before starting the rubber ball cleaning pump. 9.7 9.8 Notice to monitor the temperature variation of tile to avoid the accident of tile burning. The personnel must wear safety helmet on the commissioning site, the leaders must inspect the following possibly dangerous works on the job site, and eliminate the hidden dangers, such as dropping, electric shock, scald, be injured by rotating machine, etc.

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

9.9

If the safety of person or equipment is endangered during commissioning, the commissioning works should be stopped immediately and set the equipment at the lowest energy consumption state.

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

10. Appendix
Appendix 1. Checklist for requirements of commissioning
No. 1. 2. Examination content Installation of rubber ball pump Rubber ball cleaning pipe system Requirement Have been completely finished and recorded all technical data Have been finished completely Examination date Examination results Remarks

3.

Electric test of motor

The test is qualified. The situation is good after 2-hour operation without load, and the rotation direction is correct. Finish the test and qualified to put into use. is

4. 5.

Program control of rubber ball cleaning Electric valve and adjusting valve of each sub-system Ball collecting screen and switch valve Ball loading chamber Electric and thermal meters Road on the trial run site Communication equipment on the trial run site Fire-fighting equipments Maintenance personnel (including electric and thermal personnel) Maintenance tools and materials Operation tools and record form Measurement instruments and meters

The switch of distant operation is flexible and the direction is correct. The switch of operation is flexible and the direction is correct. Cleaned up The installation is complete, and can be used after verification Open road, sufficient illumination and reliable emergency illumination Convenient and available Sufficient Sufficient and have been trained Sufficient Have been prepared well Have been prepared well
Vibrometer Tachmeter Listening rod

6. 7. 8.

9. 10. 11. 12. 13. 14.

15.

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Remarks

Signature of commissioning leader: Date:

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

Appendix 3. Commissioning record of electric valve


KKS Code Name Correct on-the-spot indication Operation on MCC panel Correct Correct direction feedback Operation by computer Correct Correct direction feedback Time Date Open Close Remarks

Outlet electric valve of rubber ball pump A Outlet electric valve of rubber ball pump B Outlet electric valve of ball loading chamber A Outlet electric valve of ball loading chamber B Ball collecting screen A Ball collecting screen B

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Rubber ball cleaning system commissioning measure

Appendix 4. Record of trial run parameters for the rubber ball cleaning system
No. 1 2 3 4 5 6 Item Current of rubber ball pump Outlet pressure of rubber ball pump Pressure of circulation water Bearing temperature of motor of rubber ball pump Bearing vibration of rubber ball pump Bearing vibration of motor of rubber ball pump Unit A MPa MPa m m Data

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