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Indiabulls

Indiabulls

COMMISSIONING PROCEDURE
AIR PRE HEATER

NASHIK POWER PROJECT
INDIABULLS POWER LTD.
5 X 270 MW

COMMISSIONING PROCEDURE AIR PREHEATER S No. LIST OF CONTENT 1 PLANT DETAIL 2 OBJECTIVE 3 PROPOSAL 4 SERVICES REQUIRED 5 SAFETY PRECAUTIONS 6 EMERGENCY PROCEDURE 7 STATE OF THE PLANT 8 METHOD 9 COMPLETION CRITERIA 10 APPENDICES a) LOG SHEET INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 2 .

8 Water wash system 1.11 Plant item completion list for Mechanical.10 Rotor stoppage alarm 1. 1. 1.1 A. 1. Electrical and C & I are to be prepared at site. INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 3 .4 Rotating elements with support and guide bearing arrangement with forced lubrication system.2 Air Motor – 1 No.5 Soot blower system.9 Observation ports and light arrangement 1. STATUS 1 PLANT DETAIL Rotary Air Preheaters supplied are of Tri-Sector type and Separate APH (2 Nos. COMMISSIONING PROCEDURE AIR PREHEATER S No.12 Oil carry over probe.C Driven Motor – 1 No 1. 1.6 Fire Sensing device.7 Deluge system 1. Rotary Air. 1.in each circuit) are given for Primary & Secondary Air Circuits.3 Drive Gear Box.Preheater generally comprises the following. (with connected pipings & fittings) 1. 1.

4 Commissioning of Air Motor and APH operation for 10 minutes through Air Motor. 3.12 For the following system.3 Trial run of APH through main motor for 4 Hrs. a) Guide Bearing Lub-oil System b) Support Bearing Lub-oil system c) SB swivel arm sweep d) Deluge system e) Water wash system f) Air Supply to Air Motor 2 OBJECTIVE To commission the rotary air Preheater and make it available for commissioning and operation of the main plant. 3. Commissioning of rotation of rotor. refer drawings mentioned. INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 4 . 3. COMMISSIONING PROCEDURE AIR PREHEATER 1.2 Trial Run of Main Drive Motor for 8 Hrs. 3. 3.1 Acid cleaning & oil flushing of Lub-oil system of support & Guide bearings.5 Commissioning of soot Boiler system 3. 3 PROPOSAL Commissioning of the rotary air preheater is proposed in the following steps.6 Flushing of Deluge and Water wash system.

T supply 4.1 Debris in and around APH shall be removed 5. 4. 4. 4.3 Manhole doors kept open for inspection should be clearly guarded from any unauthorized persons entering in to APH. 4. INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 5 .2 Approach / stair case / platform wherever required are made available.2 Availability of operating personnel to co-ordinate the activities. 4. 5 SAFETY PRECAUTIONS 5.7 Availability of Equipment cooling water. (Test team leader to ensure this) 5. 4. 5.1 Availability of manpower with required Tools for attending to any leak.5 Availability of service water 4. cleaning of filters.4 Availability of portable fire fighting equipments near test area.5 Operation of local start / stop PB is ensured for perfect operation to facilitate stopping of APH in case of necessity.10 Availability of steam for soot blowing. COMMISSIONING PROCEDURE AIR PREHEATER 4 SERVICES REQUIRED 4. 4. 5.9 Availability of plant air.3 Availability of lighting arrangements and communication in the operating floors.4 First aid test available near test area.8 Availability of sufficient quantity of lub oil.6 Availability of L.

10 Soot blower and its connected piping are erected and kept ready for operation. (Equipment Cooling water System) 7. 7 STATE OF THE PLANT 7. 7.1 The test team should be aware of the procedure to be adopted in case of damage to machinery or injury to any personnel connected to the activity.3 All local instrumentation of Lub-oil system completed. 7.8 Deluge and water wash lines are erected upto APH and drainage facility is ensured. (List to be mutually prepared at site). 7.6 Cooling water for support and guide bearing lub oil system is available for operation.1 APH and its associated system are erected as per recommended drawing.2 The test team should be well aware of procedures to be adopted in case any abnormality in the activity. 7. Ensure either steam or air (temporary INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 6 .5 Plant Air is available upto APH. COMMISSIONING PROCEDURE AIR PREHEATER 6 EMERGENCY PROCEDUES 6. 6.2 Acid cleaning of support and guide bearing Lub-oil line completed. 7. 7.4 Power supply systems for the pumps are commissioned and available for operation. 7.7 Required local / remote C & I inputs for APH are made available.9 APH fire sensing thermocouples are commissioned and kept ready for operation. 7.

12 All erection log sheets are filled and signed by concerned agencies 7. COMMISSIONING PROCEDURE AIR PREHEATER source) is made available for commissioning APH during APH start up till main steam source is made available. 7.22 Air Seal cover and water shield of support bearing and air seal cover of guide bearing are erected as per drawing. 7.14 Dampers at inlet and outlet of APH (flue gas) are made free and connected to its drive. 7.19 Insulation of APH should be completed in all respect before boiler light up with special attention given to Guide bearing area. All loose materials / debris lying on the dampers are cleared. 7.21 Aluminum finger tabs sets installed after seals are set to the specification. 7. Local instrumentation of the gear drive completed.20 Platforms. 7. 7.23 Hot end tracking arrangements are mounted properly and the INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 7 .17 Filters in the lub-oil system cleaned and put in position. 7. Ladders and other structures around APH are inspected and thermal expansion of APH casing in all direction ensured. (Refer O & M Manual).18 Oil level in the main gear drive ensured up to its normal level.11 Oil in support and Guide bearings and fluid coupling are filled up with recommended oil up to correct level. 7. 7.15 Main motor (AC-1 No) is kept decoupled from fluid coupling.16 Service air line connection to Air Motor is complete with lubricator cum Regulator. 7.13 Flue gas ducts and Air ducts connections to APH are completed and ducts are cleared for any loose material or debris. 7. Expansion bellows connected to APH should be checked for removal of all temporary braces.

oil lines are dismantled and acid cleaned following the steps given in the procedure. 7. 7.27 Lock nuts of axial seal plate adjusters are fully tightened. COMMISSIONING PROCEDURE AIR PREHEATER system is free to move. 8.24 Breathers of bearing are checked for clean condition.3. 8. 7. 8 METHOD 8.26 Adjuster nuts of sector plates are fully tightened and locked to specification 7.32 Air receiver tank is ready and filled with air. 8.1 After completing the erection of the lub -oil system. 7.2 Ensure all P&I checks are complete and are kept in service.30 Oil carry over probe with cooling arrangement erected.3 Acid cleaning and Oil Flushing of lub-oil system of support and Guide Bearing system. 7.25 Light assembly and observation ports are in position and wired. 7.2 Motors of Lub-oil system are decoupled from pump and after INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 8 . 7.28 Entire APH plant inspected and ensured that all loose material are removed and all personnel are away from rotating equipment.1 All related standard check list are duly filled. 8.29 All manhole doors are closed except one or two as decided by the test team leader.3.31 Air preheater “standstill” alarm system is made ready. 7.

Continue oil flushing till the pump discharge pressures stabilizes for a period of 4-6 Hrs 8.1 After ensuring the insulation resistance of the motor at satisfactory level. After correcting the direction of rotation.0 KSC above the normal operating pressure of the lub- oil system.3. the pump discharge pressure will be around 2.7 Relief valve in the pump (or mounted in the discharge line) are set at 2. if found necessary.3 After completion of motor trial run. it indicates chocking of the filter and requires cleaning. COMMISSIONING PROCEDURE AIR PREHEATER ensuring Insulation resistance at satisfactory level. 8. No local current measured during this trial run. the filters are cleaned again and put back in to the system. both pump and motor are coupled.4. motor bumped and direction of rotation observed. the motor put on 4 Hrs trial run.3. 8. motor started.6 After completing the oil flushing. Motor) 8.8 For safety reasons.4 Pump primed sufficiently and then started and ensured that the entire system is filled and oil circulation established. direction of rotation checked and put on 4 Hrs trial run.3. 8.3. INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 9 . the filters in the System are closely observed in terms of increase in pump discharge pressure and filters are cleaned. 8.C. the oil flushing activity to be performed during day time.0 KSC and if an increase of around 1 KSC is observed.0 KSC to 3.3. the bearing itself is the oil reservoir and oil circulated back to Bearings through filler and cooler) Leaks attended if noticed during oil circulation. Motor no load current and vibration are noted once during the trial run.4 Air pre Heater (A. 8. 8.3.5 Initially. Normally. (In the case of lub-oil system of both guide and support bearing.

start to be electrically ensured. 8. Log readings to be made.6 Observe of a) Load current (To be logged) b) Vibration of motor and gear unit (To be logged) c) Rubbing of Seals / Aluminium finger taps. Any abnormal sound noticed to be brought to the notice of the team leader.5 Start the main motor again and allow APH to continuously run.4.1 Ensure: a) Required air pressure (Around 5. 8.4.2 After completion of motor trial run.4.4 Start the main motor and stop it after about 10-20 secs to observe for its normal running. 8.3 Start the lub – oil system of guide and support bearing assembly and establish circulation.4. c) Operation of solenoid valve d) Pressure gauge in the Air supply line to Air motor.4.5 Air Preheater (With Air Motor) 8.5. 8. COMMISSIONING PROCEDURE AIR PREHEATER 8.4.0 KSC) at the supply header to Air motor b) Lubricator filled with oil. (Rubbing of Seals do take place in cold condition and the team leader to ensure that such rubbings are normal / abnormal) 8.2 Open the bypass valve manually and slowly operate air motor vis-à-vis the APH INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 10 . 8.4.7 Trial run of APH for 2 Hrs to be carried out with AC motor. 8. motors are coupled to APH main gear drive through fluid coupling.5.8 Auto. 8.

6. INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 11 .3 Operation of air motor vis-à-vis APH carried out for about 10 minutes. the SB motor started and put on 4 Hrs trial run. No load current logged once during the trial run.6.5 Rotate APH with manual handle. e) Limit switches for sweep limit with its electrical connections. 8. 8. g) Cleanliness of the nozzles.1 After ensuring the insulation value of the motor winding at satisfactory level.6.2 Ensure: a) Coupling of motor with speed reducer b) Coupling of Speed reducer & gear box c) Erection completion of swivel link arrangement with gear d) box and swivel arm. The same operation carried out by operating the solenoid valve in the main line and APH operated for 10 minutes. 8.3 Start the SB motor and observe for the entire operation of steam nozzle movement from in board location to out board location and back to in board location.5. the air motor is commissioned during erection of APH to facilitate erection process. h) Air line connection to APH SB 8.6 APH Soot Blower 8. 8. f) Recommended lubrication of speed reducer & gear box.6.4 Set the limit switches for: a) Operating steam valve and b) Stopping the SB at its parking location. Note: Normally.5.5. COMMISSIONING PROCEDURE AIR PREHEATER 8. 8.4 Interlock operation of APH running through Air motor checked by creating the condition of electrical motor tripping.

8. 8. All these systems are commissioned separately through respective sections in the O & M manual.2 The line is charged up to system inlet isolating valve and flushed sufficiently through its drain line to plant drain till clear water observed at drain outlet.1 Other miscellaneous system: a) Rotor stoppage alarm b) Oil carry over unit c) Manual rotating of the rotor.6.1 Deluge and water wash system are similar in lay-out.7 Flushing of Deluge & Water wash system 8. At no time. 8. water allowed to get collected in APH Hoppers) 8.3 Flushing the system into the APH to be carefully done after ensuring proper draining facility at the bottom of APH (Through APH hoppers. deluge and water wash systems are isolated and APH allowed for drying (Either by natural or by running FD Fan and APH) 8. d) Light assembly for observation port e) Interlocks with other systems of the boiler.7.7.4 Flushing through both deluge system and water wash system carried out one by one sufficiently till clear water observed at drain outlet.6 Ensure the operation of APH SB from remote along with steam valve opening.5 After completion of flushing. INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 12 .5 Charge the air line slowly and blow the SB arm and nozzle sufficiently. 8. 8.8.8 General 8.7.7.6.7. COMMISSIONING PROCEDURE AIR PREHEATER 8.

I PROJECT : - UNIT NO.6) LOG SHEET . COMMISSIONING PROCEDURE AIR PREHEATER 9 COMPLETION CRITERIA 9.1 to 3.0 (Section 3. TIME PUMP IN SERVICE DISCHARGE REMARKS A B PRESSURE INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 13 .1 Air Preheater commissioning completed by carrying all the proposals given in section 3. : ACTIVITY: - S No.

II PROJECT : - UNIT NO. TIME MOTOR IN SERVICE VIBRATION REMARKS MAIN / STAND BY MOTOR APH GEAR BOX INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 14 . COMMISSIONING PROCEDURE AIR PREHEATER LOG SHEET . : ACTIVITY: - S No.

COMMISSIONING PROCEDURE AIR PREHEATER INDIABULLS CONTRACTOR MECHANICAL MECHANICAL ELECTRICAL ELECTRICAL C&I C&I COMMISSIONING COMMISSIONING Page 15 .