You are on page 1of 49

Revision: Language: Page:

HEPE 0 En & Ch 1/49 Mahan-HPE-A-


Dept: File no.:
Commissioning Harbin Huitong Electric Power Engineering Co., Ltd.
Project: Plant section:
Commissioning Project Administration
Prepared: Checked: Approved:
Li Dongdong Wang Xin liudajun
Form No.:
HTF-C-20-01 Commissioning Documentation
Date:
2011-3-11 Commissioning Program

Commissioning Program
For
Mahan 2×600MW TPP

Approved: Liu Hong


Checked: Zhou Wenxin
Prepared: Liu Dajun

Harbin Power Engineer Co., Ltd.

Harbin Huitong Electric Power Engineering Co., Ltd



Department: Page:
Content
Commissioning 2/49

Content
1. PROJECT DESCRIPTION ............................................................................................................................................ 3

1.1 GENERAL..................................................................................................................................................................... 3
1.2 TECHNICAL SPECIFICATION ........................................................................................................................................ 3

2. APPLICABLE STANDARDS ........................................................................................................................................ 5

3. COMMISSIONING ORGANIZATION .......................................................................................................................... 5

3.1 ORGANIZATION CHART ............................................................................................................................................... 5


3.2 RESPONSIBILITY FOR COMMISSIONING TEAM (HEPE) .............................................................................................. 5
3.3 THE DIVISION OF STARTING COMMISSIONING WORK .................................................................................................. 7

4. WORKING SCOPE AND ITEMS OF PRE-COMMISSIONING ............................................................................. 10

5. INSTALLATION AND PRE-COMMISSIONING ACCEPTANCE OF SIGNATURE PROCEDURES .............. 23

6. ITEMS FOR INDIVIDUAL SYSTEMS COMMISSIONING AND OVER-ALL START-UP COMMISSIONING.................. 24

7. ACCEPTANCE AND SIGNATURE OF INDIVIDUAL SYSTEM COMMISSIONING ......................................... 39

8. ACCEPTANCE AND SIGNATURE OF OVER-ALL START-UP COMMISSIONING ........................................ 39

9. PRINCIPLES OF QUALITY ASSURANCE .............................................................................................................. 40

10 . PROCESS OF OVER-ALL START-UP ................................................................................................................... 40

11. PREREQUISITES FOR OVER-ALL START-UP ................................................................................................... 41

11.1 Field and infrastructure conditions: ...............................................................................................41

11.2 Prerequisites for boiler and auxiliary equipment start-up ...................................................................42


11.3 Prerequisites for turbine and auxiliary equipment start-up: ................................................................43
11.4 Prerequisites for C&I system for unit start-up .....................................................................................43
11.5 Prerequisites for electrical system start-up: .......................................................................................44
11.6 Prerequisites for chemical systems: ...................................................................................................44

12. UNIT START-UP PROCEDURE ............................................................................................................................... 45

12.1 No- load operation Procedure ............................................................................................................45


12.2 Loaded operation Procedure ..............................................................................................................45
12.3 Full- load operation Procedure (Reliability test) .................................................................................46

13. COMMISSIONING PROCEDURE LIST ................................................................................................................. 48

Mahan-Y-HPE-A-01 R e v . 0 Issue Date:11/03/2011 2/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 3/49

1. Project Description

1.1 General
India Mahan 2 × 600MW power plant Project is located in Gujarat state India, with a total
capacity of 2 × 600MW coal-fired steam turbine-generator sets, which the main equipments
are: the boilers from the Harbin Boiler Co., Ltd. (HBC), steam turbines from Harbin Turbine
Co., Ltd. (HTC), and generator supplied by Harbin Electric Machinery Co., Ltd.(HEC).
Mahan Project is scheduled that # 1 unit will be synchronised in 2011, # 2
unit will be synchronised in 2011.

1.2 Technical Specification



Boiler:
Boiler is manufactured by HBC. Its type as follow: Sub-critical parameters, controlled
circulation, single furnace, four corners tangential-firing type, single reheat, balanced draft,
solid slagging, outdoor laid, complete steel structure hanging construction, Π-type boiler with
a single drum.
Main technical parameter as follow:
Model: HG-2060/17.5-YM9
BMCR condition:
Main steam flow: 2060t/h
Main steam pressure: 17.5MPa(g)
Main steam temperature: 541℃
Reheat steam outlet flow: 1725.9t/h
Reheat steam outlet Pressure: 3.817MPa(g)
Reheat steam outlet temperature: 541℃
Reheat steam inlet pressure: 4.007MPa(g)
Reheat steam inlet temperature: 335℃
Economizer inlet feed water pressure: 19.492MPa(g)
Economizer inlet feed water temperature: 281℃
Flue gas air preheater outlet temperature (unrevised): 138℃
Flue gas air pre-heater outlet temperature at (revised): 131℃
Boiler efficiency (based on HHV) (TMCR): 87.1%

Turbine:
Manufacturer: HTC
Type:Sub-critical, single reheat, three cylinders and four flow exhausting, condensing

SLY-HPE-A-01 R e v . 0 Issue Date 3/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 4/49

Main technical parameter as follow:


Model: N600-16.7/538/538
TMCR
Rated power: 600MW
Rated main steam flow: 1866.68t/h
Main steam pressure(rated): 16.7Mpa(a)
Main steam temperature(rated): 538 ℃
Reheat steam flow: 1572.73t/h
Reheat steam temperature: 538℃
Heat rate (TMCR condition, 0% makeup water): 8122.40kJ/kWh
Rated back pressure: 9.60kPa(a)
Rated circulating cooling water temperature: 33℃
Rated speed: 3000r/min
Maximum output(VWO): 649.74MW
Max. steam flow of main steam(VWO): 2060t/h
Rated feed water temperature: 275.3℃
Generator
Manufacturer: HEC.
Main technical parameter as follow:
Model: QFSN-600-2YHG
Rated output: 705.88MVA
Rated output: 600MW
Rated efficiency: ≥98.85%
Excitation type: static excitation
Cooling mode: water-hydrogen-hydrogen
Rated hydrogen pressure: 0.40MPa(g)
C&I System
Mahan Project is applied Distribute control system of boiler, turbine and generator. Two
Units use one Centralized Control Room, One Distribute Control System(DCS) is used in
each Unit. That Following function can be realized.
A. It is operated for Start-up and shut-down of power plant in Centralized Control
Room.
B. Monitoring and adjusting of normal operation condition can be realized in
Centralized Control Room.
C.Emergent operation for accident or abnormal conditions can be realized in Centralized
Control Room.

SLY-HPE-A-01 R e v . 0 Issue Date 4/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 5/49

D. Coordinated Control, Turbine Follow, Boiler Follow and Manual Modes can be put-into
service during Start-up and normal operation , achieve optimization control of Power
Plant.

2. Applicable Standards

2.1 Documentation and materials of design and manufacture


2.2 Contract requirements for commissioning operation.

3. Commissioning Organization

3.1 Organization Chart


Mahan Project Commissioning department is built up according to Manager Assumes
Responsibility System, ensure the smooth delivery of commissioning work.

Organizational and managerial Framework

Commissioning
Director (CD)

Deputy CD.

Speciality Safety Engineer QAC Engineer


Managers

Planning Documentation Secretary


Engineer Engineers
Engineer

3.2 Responsibility for Commissioning team (HEPE)


3.2.1 Commissioning director

SLY-HPE-A-01 R e v . 0 Issue Date 5/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 6/49

a) Commissioning director is responsible for HPE commissioning work of the project , as the
principal of the safety of commissioning activities,
b) Organize all person of department to implement commissioning mobilization (to collect
information, survey commissioning, prepare for test instruments and test procedures)
c) Organize to issue Commissioning Program, Commissioning Organization Chart and
Commissioning Plan Schedule.
d) Responsibility for performing and controlling of Commissioning work, managing and
supervising Commissioning progress.
e) Responsibility for turning-over of commissioning documents.
3.2.2 Deputy Commissioning Director
a) Assist Commissioning Director to plan Commissioning Schedule.
b) Assist Commissioning Director finish management of supervising and Checking during
commissioning process.
c) Organize to edit Commissioning procedure, commissioning plan and other
commissioning documents.
d) Organize to edit Commissioning quality control plan, commissioning implement and
examination.
e) Organize compiling turn-over document.
3.2.3 Quality Control Engineer
a) Issue Commissioning Quality Control Procedure
b) Organize compiling Commissioning Record, such as commissioning tables,
Commissioning Test Tables, Protection and Automatic equipments Record, etc.
c) Organize compiling Standards of turn-over documents.
d) Check and assess Commissioning quality
3.2.4 Safety Engineer
a) Compile commissioning Safety examination procedure and supervise implementation.
b) Be responsible for Commissioning Safety management on site.
3.2.5 Document Engineer
a) Compile Commissioning document management procedure and supervise
implementation
b) Be responsible for handing in and out of commissioning documents.
3.2.6 Commissioning Manager
a) Be chiefly responsible for safety of speciality
b) Be responsible for compiling documents of speciality; organize commissioning personnel
to finish work according to commissioning procedures.
c) Be responsible for harmony, organization and implement of commissioning.

SLY-HPE-A-01 R e v . 0 Issue Date 6/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 7/49

d) Fill-in daily working record, shift turning over records.


3.2.7 Responsibility of commissioning engineers
a) Carry out commissioning work leading by speciality manager.
b) Edit commissioning procedures and commissioning reports.
c) Implement commissioning works according to approved commissioning procedures and
schedules.
d) Finish commissioning records
e) Finish turning over of commissioning documents

3.3 The division of starting commissioning work


The project commissioning work includes pre-commissioning, individual system
commissioning and over-all start-up Commissioning, in which the scope of
pre-commissioning that includes but doesn’t limit single equipment commissioning and single
motor commissioning belongs to ESSAR Construction, and individual system commissioning
and over-all start-up Commissioning works are carried on by HEPE. All these above works
are for equipments that HPE supplied. For the commissioning work of ESSAR equipments,
they will be done by ESSAR.
The unclear working boundary will be coordinated and determined by the Acceptance
Committee of Commissioning (ACC) under charge of HPE.
3.3.1 HPE
(1) Responsible for setting up the Acceptance Committee of commissioning (ACC) and its
Coordinating Headquarter (CH). And it will organize and manage the whole process of
over-all start-up and trial operation.
(2) To participate in all phases of routine work of trial operation inspection coordination,
transfer of inspection and the final acceptance.
(3) To coordinate the implementation of the resolution of contractual issues and external
relations
3.3.2 ESSAR Construction (Include Construction Supervisor)
(1) Be responsible for the completion of all civil and installation work, as well as temporary
works that ACC request.
(2) All civil, construction and commissioning operations must obey CH commands since CH
is built up.
(3) Be responsible to support to individual system commissioning work and unit start-up work
during the whole trial run period.

SLY-HPE-A-01 R e v . 0 Issue Date 7/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 8/49

(4) Be responsible for completing the pre-commissioning and Single equipment trials
operation, and be accepted by the HPE.
(5) Submit records of the pre-commissioning and related documents, information
(6) Prepare for the equipments’ safety isolation of commissioning.
(7) Be responsible for on-site equipments security, fire protection, public security, to
eliminate defects and maintain the equipments
(8) Be responsible for eliminating construction defects during the performance test and
warrantee period.
(9) To submit all documents supporting the units, spare parts and special tools
(10) To support the designer to complete the built drawings.
(11) To participate the commissioning, performance testing phase of the work of the various
duty positions.
(12) Strictly carry on the safety rules and regulations of unit commissioning work.
3.3.3 Commissioning team (Carrying out the responsibility of CH)
(1) Be responsible for the preparation of commissioning Program according to the contract.
(2) Edit the commissioning procedures for individual system commissioning and over-all
start-up.
(3) Review of pre-commissioning procedures.
(4) To attend the witness acceptance test of major equipments during pre-commissioning.
(5) Comprehensive inspection the rationality of all systems for overall start-up (including
BOP part)
(6) Organize and coordinate overall start-up and trial operation.
(7) Be responsible for proposing suggestion to solve the major technical problems during
the trial operation.
(8) To submit commissioning report.
3.3.4 ESSAR Power
(1) Responsible for the start-up mobilization of commissioning, including consumptions
such as fuel, water, steam, gas, acid, alkali and other material supply;
(2) To provide the electrical, C&I and other operational setting values for ESSAR equipment
and systems.
(3) To participate and witness the acceptance test items of the contract (or mutually agreed
upon)
(4) Prepare for the safety of isolation of operating equipment and test equipment
(5) Strict implementation of the commissioning safety rules and regulations.
(6) During individual system commission, over-all start-up and trial run in charge of
start-stop operation , operation adjustment, incident handling works.

SLY-HPE-A-01 R e v . 0 Issue Date 8/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 9/49

(7) Review commissioning programs and procedures, and to operate the relevant
equipments and system for requirements of commissioning engineers;
(8) To organize the qualified operators and maintenance workers in service, strictly carry
out the operation regulations, and accept the request of HPE operation supervisors.
(9) Complete the commissioning of ESSAR equipments and system in time according to the
commissioning schedule.
(10) Be responsible for organizing and coordinating the relevant Indian departments to
ensure the commissioning progress.
(11) Be responsible for supplying System Flow Drawings, Operation Manuals, Maintainance
Manuals and other documents of ESSAR equipments.
3.3.5 Equipment Vendors
(1) Supply on-site service and guidance to ensure that equipment performance;
(2) Eliminate the equipment defects in time;
(3) Be responsible for handling with problems;
(4) Associated with the commissioning unit to complete the commissioning of equipment,
and acceptance by the commissioning unit and the ESSAR Power;
(5) Be responsible for on-site installation, commissioning and operating personnel’ technical
guidance and training, to ensure the normal operation of related equipment and
maintenance.
3.3.6 HPE Operation Supervision Team
(1) Responsible for the preparation of the operating regulations and safety rules.
(2) Be responsible for command and operation in emergency.
(3) Assist ESSAR for operation management, and verify ESSAR qualified operators in
service. .
(4) To set up the operation position and turn-over regulation.
(5) To supervise the implementation of regulation of “permit to work” (PTW).
(6) To carry on the Responsibility of shift engineer.
3.3.7 Design Institute
(1) Responsible for solving design problems in the start commissioning, make the
necessary design changes in timely
(2) To participate in the work of trial operation command headquarters.

SLY-HPE-A-01 R e v . 0 Issue Date 9/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 10/
10/49

.Working Scope and Items of Pre-commissioning


4.

4.1 Boiler
4.1.1 Air fan pre-commissioning
1)Protection calibration of Single equipment trial running;
2) The first start-up check of air fans;
3) Power oil press adjustment and move leaf transmission test of axial flow type air fan;
4) Checking and parameter adjustment of air fan lubricate cooling equipment system;
5) With electric Single equipment motor idle running;
6) Fan trial running;
7) Measuring temperature and vibration of bearing and other parts ;
8) Note trial running parameter;
9) To check and deal with trial running exceptional situation.
4.1.2 Coal mill pre-commissioning
1) Protect calibration of Single equipment trial running;
2) Coal mill oil system inspection and adjustment;
3) Spring loading system inspection and adjustment;
4) Export separation damper adjustment;
5) The first start-up check of coal mill;
6) With the electric Single equipment motor idle running;
7) Coal mill trail running;
8) Measuring temperature and vibration of bearing、slowdown machine and other parts;
9) Note trial running parameter of coal mill;
10) To check and deal with trial running exceptional situation.
4.1.3 Coal feeder pre-commissioning
1) Protection calibration of Single equipment trial running;
2) The first start-up check of feeder;
3) With the electric motor trail running of single equipment;
4) Coal feeder trail running;
5) The necessary clearance and belt tension adjustment;
6) Measuring temperature and vibration of bearing and other parts;
7) Record trial running parameter of feeder;
8) To check and deal with trial running exceptional situation.
4.1.4 Fuel oil pump pre-commissioning
1) Calibration for protection and interlock of single equipment;
2) Supporting the electric motor trial running;

SLY-HPE-A-01 R e v . 0 Issue Date 10/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 11/
11/49

3) System check and trial running with pumps;


4) Note trial running parameter;
5) Fuel oil system flushing;
6) Sump pump trial running and waste oil deal with separate equipment trail running;
7) To check and deal with trial running exceptional situation.
4.1.5 Air pre-heater pre-commissioning
1) Individual machine sequence control commissioning;
2) To interlock protection test;
3) Water flushing devices and fire fighting equipment are checked;
4) To check and parameter adjustment of oil cooling system;
5) Seals adjustment in Cold condition;
6) Air pre-heater Single equipment trial running;
7) Note Single equipment trial running parameter;
8) To check and deal with trial running exceptional situation.
4.1.6 Soot blower pre-commissioning
1) To check before soot blower commissioning;
2) Soot blower running and advance and retreat adjustment test;
3) Soot blower into inspection and fault handing.
,air-powered valves and adjustment valves pre-commissioning
4.1.7 Electric valves,
1) Mechanical tuning switch position;
2) With electrical、thermal control and commissioning workers setting switch position;
3) Hand, air-powered and electric valves switching action test;
4) Valve total excursion test;
5) Adjustment valves calibration test.
4.1.8 Other equipment of boiler and subsidiary coal handing, dispose of clinker and
other systems pre-commissioning.

4.2 Turbine
4.2.1 Water pump pre-commissioning
1) Single equipment commissioning related interlock and check protection
2) Working in electric specialty to process motor commissioning
3) Checking system and Pump commissioning
4) Measuring and checking every part of temperature、oil level and vibration
5) Operating condition and parameter of adjusting, monitoring
6) Record the commissioning parameters

SLY-HPE-A-01 R e v . 0 Issue Date 11/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 12/
12/49

7) Checking and deal with commissioning abnormal conditions.


4.2.2 Oil pump single equipment pre-commissioning
1) Single equipment commissioning related interlock and check protection
2)Coordinate with electric engineers to process motor commissioning
3) Checking trial run of system and pump.
4) Measuring and checking every part of temperature、oil level、vibration
5) Operating condition and parameter adjusting, monitoring
6) Record the commissioning parameter
7) Checking and deal with commissioning abnormal conditions
4.2.3 Circulating water pump single equipment pre-commissioning
1) Single equipment commissioning related interlock and check protection
2)Coordinate with electric engineers to process motor commissioning
3) Checking trial run of system and pump.
4) Measuring and checking every part of temperature、oil level、vibration
5) Operating condition and parameter adjusting, monitoring
6) Record the commissioning parameter
7) Checking and deal with commissioning abnormal conditions
4.2.4 Condensate water pump pre-commissioning
1) Single equipment commissioning related interlock and check protection
2)Coordinate with electric engineers to process motor commissioning
3) Checking trial run of system and pump.
4) Measuring and checking every part of temperature、oil level、vibration
5) Operating condition and parameter adjusting, monitoring
6) Record the commissioning parameter
7) Checking and deal with commissioning abnormal conditions
4.2.5 Vacuum pump pre-commissioning
1) Single equipment commissioning related interlock and check protection
2)Coordinate with electric engineers to process motor commissioning
3) Seal water washing and adjust the water level control equipment.
4) Checking trial run of system and pump.
5) Measuring and checking every part of temperature、oil level、vibration
6) Operating condition and parameter adjusting, monitoring
7) Record the commissioning parameter
8) Checking and deal with commissioning abnormal conditions
4.2.6 Motor valve, pneumatic valve and control valve’s pre-commissioning
1) Adjusting Switch mechanical position

SLY-HPE-A-01 R e v . 0 Issue Date 12/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 13/
13/49

2) Coordinate with electric, I & C commissioning personnel for switch position adjusting.
3) Valve manual operation, pneumatic and motor-driven changing-over test.
4) Valve total travel test
5) Control valve check test
4.2.7 Turbine other equipment and individual system concerned pre-commissioning.

4.3 Electricity
4.3.1 Electric Equipment
)Generator Pre-commissioning
1)
1. Measure stator winding’s insulation resistance and absorption ratio or polarization
index;
2. Measure stator winding’s DC resistance;
3. DC HV withstand test and leak current measurement of stator winding;
4. AC HV withstand test of stator winding;
5. Measure rotor winding’s insulation resistance;
6. Measure rotor winding’s DC resistance;
7. AC HV withstand test of rotor;
8. Measure insulation resistance of excition circuit of generator or exciter and all
equipments connected to them, do not include generator rotor and exciter armature;
9. Measure insulation resistance of generator and exciter insulated bearing and rotor
water inlet holder;
10. Check embedding temperature measuring meter;
11. Measure DC resistance of deexcitation resistance and automatic synchronous
resistance;
12. Measure AC impedance and power loss of rotor winding at static condition.
)Power Transformer pre-commissioning
2)
1. Chromatogram analysis of gas dissolved in oil
2. DC resistance of winding
3. Winding’s insulation resistance, absorption ratio or (and) polarity index
4. tgδ of winding
5. tgδ and capacity of capacitive bushing
6. Insulation oil test
7. AC HV withstand test
8. Insulation resistance of iron core with external earth line
9. Insulation resistance of core through typed bolt, iron yoke clamp, steel belt for

SLY-HPE-A-01 R e v . 0 Issue Date 13/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 14/
14/49

colligation, iron core, coil ring and shield etc.


10. Water quantity in oil
11. Gas quantity in oil
12. Winding leakage current
13. Voltage ratio of all winding tap position
14. Check three-phase transformer vector or single-phase transformer polarity
15. No-load current and no-load power loss
16. Short circuit impedance and on-load loss
17. Partial discharge measurement
18. On-load tap changer test and check
19. Temperature measurement device and secondary circuit test
20. Gas relay and secondary circuit test
21. Pressure relief relay check
22. Sealing check of whole unit
23. Cooling device and secondary circuit check
24. Bushing CT insulation test
25. No-load closing CB at full voltage
)Excitation System Pre-commissioning
3)
1. Deexcitating panel commissioning, deexcitating CB operation test, opening-closing
time measurement of main contactor and deexcitating contactor
2. Primary equipments commissioning and local operation test of deexcitating
resistance, field rheostat, induction booster, isolation transformer, commutate panel
and rotor deexcitation overvoltage protection device etc.
)PT and CT pre-commissioning
4)
1. Current Transformer
a) Insulation resistance of winding and terminal
b) tgδ and capacitor
c) Chromatogram analysis of gas dissolved in oil
d) AC HV withstand test
e) Partial discharge measurement
f) Polarity check
g) Ratio check of all tap position
h) Check excitation characteristic curve
i) Sealing check
j) DC resistance measurement of primary winding
k) Breakdown voltage of insulating oil

SLY-HPE-A-01 R e v . 0 Issue Date 14/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 15/
15/49

2. Potential Transformer
a) Insulation resistance
b) Chromatogram analysis of gas dissolved in oil
c) AC HV withstand test
d) Partial discharge measurement
e) Measure no-load current
f) Sealing check
g) Insulation resistance of iron core clamped bolt which can be connected
h) Vector group and polarity
i) Voltage ratio
j) Breakdown voltage of insulating oil
)Circuit Breaker pre-commissioning
5)
1. SF6 gas humidity and other inspection items of CB
2. SF6 gas leakage test
3. Insulation resistance of auxiliary circuit and control circuit
4. HV withstand test
5. AC HV withstand test of auxiliary circuit and control circuit
6. Insulation resistance, capacity and tgδ of shunt capacitor between contactors
7. Closing resistance and acting time
8. Speed characteristic of CB
9. CB’s time parameter
10. acting voltage of opening and closing electromagnet
11. Contacting circuit resistance
12. DC resistance of opening and closing coils
13. Check SF6 gas density monitor including setting value
14. Check or regulate pressure meter, check mechanism operating pressure settings
including gas pressure and liquid pressure, check mechanical safety valve
15. Operating pressure fall value when operation mechanism opening, closing or
reclosing
16. Liquid or gas pressure operation mechanism leakage test
17. Running time of oil or gas pump pressure compensating and filling from zero
18. Slowly open with pressure loss preventing of liquid pressure mechanism and
pneumatic mechanism adopting gas differential principle
19. Acting characteristic of auxiliary control devices for interlock, anti-jump and anti-close
at phase displacement
20. CT, PT and arrester

SLY-HPE-A-01 R e v . 0 Issue Date 15/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 16/
16/49

)Disconnector and Load Switch pre-commissioning


6)
1. Insulation resistance of organic material holding isolator and step up pole
2. Insulation resistance of secondary circuit
3. AC HV withstand test
4. AC HV withstand test of secondary circuit
5. Minimum acting voltage of motor-drived, pneumatic-drived or liquid pressure
operation mechanism coil
6. Measure conductive circuit resistance
7. Operation mechanism action situation
)Reacter and Arc Extinguish Coil pre-commissioning
7)
1. Chromatogram analysis of gas dissolved in oil
2. DC resistance of winding
3. Winding’s insulation resistance, absorption ratio or (and) polarity index
4. tgδ of winding
5. Insulation oil test
6. AC HV withstand test
7. Insulation resistance of core through typed bolt, iron yoke clamp, steel belt for
colligation, iron core, coil ring and shield etc.
8. Sealing check of whole unit
)Isolator and Bushing Test
8)
1. Insulation resistance of main insulation and capacitive bushing teminal to ground
2. tgδ and capacity of main insulation and capacitive bushing teminal to ground
3. Chromatogram analysis of gas dissolved in oil
4. AC HV withstand test
)Power Cable Test
9)
1 DC HV withstand test and leakage current measurement
2 Measure insulation resistances
3 AC HV withstand test
)Arrester and Capacitor pre-commissioning
10)
1. Capacitor
a) Insulation resistance of polarity to case
b) Capacity
c) Measure shunt resistance
d) Check oil leakage
2. Arrester
a) Insulation resistance

SLY-HPE-A-01 R e v . 0 Issue Date 16/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 17/
17/49

b) Leakage current at DC U1mA and 0.75U1mA


c) AC leakage current at running voltage
d) Working reference voltage at working reference current
e) Insulation resistance of seat plate
f) Check discharge counter
)Busbar HV Withstand Test
11)
1. Insulation resistance
2. AC HV withstand test
)Earthing Device Commissioning
12)
Measure earthing resistance
4.3.2 HV Static Electric Precipitator pre-commissioning
1. Test of precipitator transformer, cable, voltage transformer, current transformer and
circuit breaker
2. Earthing resistance measurement
3. Primary and secondary equipments commissioning of instrument, transducer
protection, automatic control and regulation device, shaker device, heat device,
ventilation motor etc.
4. Protection and measurement element regulation.
4.3.3 Diesel Generator Unit pre-commissioning
1. Equipment commissioning of diesel generator and exciting device, circuit breaker,
voltage transformer, current transformer, protection device, synchronization device,
measurement, cable etc.
2. Unit test
4.3.4 Auxiliary System Single equipments pre-commissioning
Auxiliary system pre-commissioning includes motor, CT, circuit breaker, cable,
protection and measurement elements regulation etc.
Motor Test:
1. Measure winding’s insulation resistance and absorption ratio
2. DC resistance of winding
3. Stator winding leakage current and DC HV withstand test
4. AC HV withstand test of stator winding
5. AC HV withstand test of wirewound motor rotor
6. AC HV withstand test of synchronous motor rotor
7. DC resistance of variable resistance or start-up resistance
8. AC HV withstand test of variable resistance or synchronous motor deexcitation
resistance

SLY-HPE-A-01 R e v . 0 Issue Date 17/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 18/
18/49

9. Insulation resistance of synchronous motor and its exciter bearing


10. AC HV withstand of rotor metal tie
11. Check stator winding’s polarity
12. Stator core test
13. Motor no-load trial run and measure no-load current and no-load power loss
14. Protection and measurement element regulation.
About CT, CB and cable tests, please refer to statement above.
Auxiliary System consists of items as follow:
1)Electric pre-commissioning of start-up boiler system
2)Electric pre-commissioning of coal transmission system
3)Electric pre-commissioning of induced draft fan and forced draft fan system
4)Electric pre-commissioning of primary fan system
5)Electric pre-commissioning of air preheater system
6)Electric pre-commissioning of fuel system
7)Electric pre-commissioning of milling system
8)Electric pre-commissioning of ash blower system
9)Electric pre-commissioning of HVAC
10)Electric pre-commissioning of ash handling system
11)Electric pre-commissioning of boiler water circulating pump system
12)Electric pre-commissioning of CCCW system
13)Electric pre-commissioning of compress air system
14)Electric pre-commissioning of OCCW system
15)Electric pre-commissioning of condensate water system
16)Electric pre-commissioning of rubber ball
17)Electric pre-commissioning of circulating water and dosing system
18)Electric pre-commissioning of water deoxygenizing and feeding system
19)Electric pre-commissioning of turbine lube oil, jacking oil and turning gear system
20)Electric pre-commissioning of boiler feed water pump oil system
21)Electric pre-commissioning of high and low pressure bypass system
22)Electric pre-commissioning of generator water cooling and hydrogen cooling system
23)Electric pre-commissioning of generator sealing oil system
24)Electric pre-commissioning of vacuum system
25)Electric pre-commissioning of shaft sealing system
26)Electric pre-commissioning of water drain system
27)Electric pre-commissioning of chemical feed water treatment system

SLY-HPE-A-01 R e v . 0 Issue Date 18/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 19/
19/49

28)Electric pre-commissioning of condensate water fine treatment system


4.3.5 Auxiliary Frequency Convertor pre-commissioning
1) Insulation resistance test
2) Initial power up
3) System testing on motor: Check E-stop logic
4) Remote start/stop
5) Remote fault reset
6) Local start/stop
7) 4 to 20mA input and output check
8) Blower operation test
9) Spinning load test
10) Non-latching run request with no medium voltage input
11) System load test
4.3.6 Protection and Automatic Device pre-commissioning
Protection device commissioning items consist of protection device and all accessory
units commissioning such as instrument and transmitter; panel wiring check; protection
setting; unit test with commissioning reports of equipments supplied by owner before
subsystem commissioning.
1) Little current grounding inspection device for less than 35kV system
2) 415V protection device
3) Transformer protection
4) Busbar protection
5) Bus coupler protection
6) Generator-transformer unit protection
7) Fault recorder
8) Automatic transfer equipment of emergency power supply (415V)
9) Automatic transfer equipment of emergency power supply (3.3kV and 11kV fast transfer)
10) Automatic synchronization device
11) Battery automatic charge device
12) UPS device
13) Generator automatic excitation device
4.3.7 Micro Computer Monitoring Unit Single equipments pre-commissioning
Commissioning items consist of view check, on-off input check, control output check,
analogue accuracy and linearity degree test, impulse accuracy test, power on commissioning,
panel wiring check, auxiliary relay transmitter check.

SLY-HPE-A-01 R e v . 0 Issue Date 19/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 20/
20/49

1)Plant micro computer monitor element


2)Step-up substation micro computer monitor element

4.4 C&I
The pre-commissioning work of C&I include:
4.4.1 Temperature instruments regulation
A. verify the whole range of instrument
B. setup the setting value of switch
C. verify the characteristic of TC and RTD of main parameter
D. checkout the correctness and commissioning
4.4.2 Pressure instruments regulation
A. verify the whole range of instrument
B. setup the setting value of switch
C. modifies the liquid column of instruments of main parameters
D. checkout the leakproofness of the pipe of instruments
E. checkout the correctness and commissioning
4.4.3 Differential pressure instruments regulation
A. verify the whole range of instrument
B. setup the setting value of switch
C. checkout the leakproofness of the pipe of instruments
D. checkout the correctness and commissioning
4.4.4 Flow instruments regulation
A. verify the whole range of instrument
B. checkout the capability and position of the sensor
C. related regulation of sensor and displaying meter
D. adjusting the switches and setup the setpoint of alarm value
E. checkout the correctness and commissioning
4.4.5 Level instruments regulation
A. verify the whole range of instrument
B. checkout the capability and position of the sensor
C. related regulation of sensor and displaying meter
D. adjusting the switches and setup the setpoint of alarm value
E. checkout the correctness and commissioning
4.4.6 Display instruments regulation

SLY-HPE-A-01 R e v . 0 Issue Date 20/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 21/
21/49

A. Analogue indications、record alarms instruments: checkout the sensitive and balance of


figure, verify the scale, test the function of output and alarm, setup the alarm point, test the
recording mechanism.
B. Digital indications、record alarms instruments: test the precision, test the function of
output and alarm, setup the alarm point, test the recording mechanism
C. Temperature instruments: graduation choice, grouping checkout, adjust the limited
value
D. Flash alarm instruments: testing the flash and alarm sound, recording, clear up testing.
E. checkout the correctness and commissioning
4.4.7 Analyzing instruments regulation
A. checkout the indicating gauge
B. check the sensor、converter and so on
C. checkout the correctness and commissioning
4.4.8 Actuators regulation
A. washing the air pipe
B. opening and opening reading checkout
C. make sure the correct direction of action
D. Terminal switch and moment switch regulation
E. test the whole range of valve
F. change over manual/motor/ pneumatic mode, and test local/remote control mode.
G. related regulation of remote and manual operation of control system
4.4.9 Supervision instruments of steam turbine and auxiliary regulation
A. index gage checkout
B. transducer checkout
C. sensor characteristic test
4.4.10 Fittings regulation
A. power supply: output regulation, stability test
B. junction compensator: test compensating performance in room temperature
C. calorstat: constant temperature performance test
D. relay: response and release voltage test
E. solenoid valve: contact point regulation
4.4.11 I/O circuit regulation
A. make sure the connecting cable is correct
B. I/O point in local is powered on
C. checkout the correction of I/O circuit
D. test the control system in static.

SLY-HPE-A-01 R e v . 0 Issue Date 21/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 22/
22/49

4.5 Chemistry
4.5.1 Supply pumps pre-commissioning
1)Test functions of interlock and protection for single equipments
2)Cooperate with electrical motor test
3)Check and test system with pump
4)Operating conditions and parameters adjustment and monitoring
5)Record operational parameters
6)Equipments inspection and troubleshooting.
4.5.2 Blowers pre-commissioning
1)Cooperate with electrical motor test
2)Check and test system with pump
3)Operating conditions and parameters adjustment and monitoring
4)Recording parameters and inspecting belt tension.
5)Equipments inspection and troubleshooting.
4.5.3 Vacuum Pump Commissioning
1)Cooperate with electrical motor test
2)Check and test system with pump
3)Operating conditions and parameters adjustment and monitoring
4)Record operational parameters
5)Equipments inspection and troubleshooting.
4.5.4 Centrifugal fan pre-commissioning
1)Cooperate with electrical motor test
2)Check and test system with fan
3)Air flow test
4)Operating conditions and parameters adjustment and monitoring
5)Record operational parameters
6)Equipments inspection and troubleshooting.
4.5.5 Dosing pump pre-commissioning
1)Inspection and test system
2)Safety Pressure test
3)Metering pump flow calibration
4)Operating conditions and parameters adjustment and monitoring
5)Record operational parameters
6)Equipments inspection and troubleshooting.
4.5.6 Air compressor pre-commissioning

SLY-HPE-A-01 R e v . 0 Issue Date 22/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 23/
23/49

1)Inspection and test system


2)Check safety valve
3)Drier pre-commissioning
4)load test
5)Record operational parameters
6)Equipments inspection and troubleshooting.
4.5.7 Mixer pre-commissioning
1)Inspection and test system
2)Mixing efficiency test
3)Equipments inspection and troubleshooting.
4.5.8 Reverse osmosis high-pressure pump pre-commissioning
1)Inspection and test system
2)Vibration measurement, high temperature, loading test
3)Record operational parameters
4)Equipments inspection and troubleshooting.
4.5.9 Condensate polishing processing recycling pump pre-commissioning
1)Inspection and test system
2)Vibration measurement, high temperature, output test
3)Record operational parameters
4)Equipments inspection and troubleshooting.
4.5.10 Machine commissioning
1)Inspection and test system
2)Output test
3)Record operational parameters
4)Equipments inspection and troubleshooting.
Note: The pre-commissioning items that are only tested on loading status, could be
carried out during individual systems commissioning assisting by HEPE.

5 Installation and pre-commissioning acceptance of signature procedures

5.1 The installation and pre-commissioning work of HPE equipment and systems is carried
out by ESSAR Construction and supervised by HPE.
5.2 HPE installation supervisors are responsible for the acceptance certificates of special
inspection.
5.3 HPE should attend witness acceptance test of the important ESSAR equipments and
systems.

SLY-HPE-A-01 R e v . 0 Issue Date 23/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 24/
24/49

5.4 HEPE should attend pre-commissioning inspection in major HPE equipment and
systems.

6. Items for Individual Systems commissioning and Over-all Start-up

Commissioning

6.1 Boiler
6.1.1 Individual Systems commissioning items
(1) Be responsible for boiler individual systems commissioning, control commissioning
progress according commissioning schedule.
(2) Verify the boiler status to satisfy the over-all start-up conditions.
(3) To participate in the work of air compressor system trial running;
(4) Air preheater and its system commissioning;
1)Check and affirm air preheater correlative single equipment commissioning was
checked and accepted.
2) Lubricating oil system and all cooling water systems checking and operation on
remote.
3) Air preheater single valves、damper with cold status and remote logic checking .
4) Interlock、protection、start-stop sequence control、alarm and other remote logic
checking of air preheater.
5) Fire-alarm equipment romote logic checking of air preheater.
6) To check and test wash water、fire water system of air preheater.
7) Blow and sweep of soot blowing auxiliary steam source associated piping of air
preheater.
8) Air preheater and related systems static inspection and acceptance.
9) Air preheater individual system trial running, fill in trail running record sheets and
acceptance.
(5) Draught fan and its system commissioning;
1) Check and confirm the draught fan single equipment commissioning acceptance .
2) Lubrication、fluid power system and each cooling water checking and operation on
remote.
3) Draught fan single valves、damper with cold status and remote logic checking
4) Interlock、protection、start-stop sequence control、alarm and other remote logic
checking.
5) Draught fan and related systems static inspection and acceptance.
6) Draught fan individual system trial running, fill in trail running record sheets and
acceptance.

SLY-HPE-A-01 R e v . 0 Issue Date 24/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 25/
25/49

(6) Forced Fans and its system commissioning;


1) Check and confirm the forced draft fan single equipment commissioning acceptance .
2) Lubrication、fluid power system and each cooling water checking and operation on
remote.
3) Forced draft fan single valves、damper with cold status and remote logic checking .
4) Interlock、protection、start-stop sequence control、alarm and other remote logic
checking of forced draft fan.
5) Forced draft fan static checking and acceptance including related systems.
6) Forced draft fan individual system trial running, fill in trial running record sheets and
acceptance.
(7) Primary air fan and its system commissioning;
1) To check and assure the certification of primary air fan single commissioning.
2) Primary air fan single lubricating、cooling water checking and operation on remote
3) Primary air fan single valves、damper with cold status and remote logic checking
4) Interlock、protection、start-stop sequence control、alarm and other remote logic
checking of primary air fan.
5) Primary air fan static checking and acceptance including related systems.
6) Primary air fan individual system trial running, fill in the trial running record sheets and
acceptance.
(8) Boiler circulating water pump and its system commissioning;
1) To check and confirm the boiler circulating water pump related single equipment
commissioning acceptance, flush pipeline of qualified.
2) Use the requirement dematerialized water filling into the boiler circulating water pump
after protection liquid was discharged over.
3) Boiler circulating water pump cooling water system checking and operation on remote
4) Related system valves boiler circulating water pump with cooling status checking and
operation on remote acceptance, and remote logic control.
5) Interlock、protection、start-stop sequence control、alarm and other remote logic
checking of boiler circulating water pump.
6) Boiler circulating water pump static checking and acceptance including related
systems
7) Start boiler circulating water pump individual system trial running after boiler upriver;
fill in the trial running record sheets and acceptance.
Note: The acid test run during the furnace pump furnace pump requires a continuous
injection
(9) Boiler start drainage system commissioning;
1) To check and confirm correlative single equipment commissioning was finished and
received.
2) Boiler drainage、discharge air and discharge sewage system related interlock、

SLY-HPE-A-01 R e v . 0 Issue Date 25/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 26/
26/49

protection、start-stop sequence control、alarm and other remote logic checking.


(10) Boiler cold aeration test;
1) Air measurement equipment calibration.
2) To do the primary air volume leveling test of each mill’s export lose coal dust tube.
3) To check the meters of combustion gases system and pulverizing system.
4) Cold air dynamic field test.
(11) Fuel system commissioning;
1) To check and confirm the fuel system related single equipment commissioning
acceptance, flush pipeline of qualified.
2) Oil pump interlocking test and low oil pressure alarm test.
3) Electromagnetic valve、quick-off valve interlocking test.
4) Oil nozzle cold status atomization test and power measurement.
5) Fuel cycle test.
(12) Secondary-air heater and its system commissioning;
1) To check and confirm Secondary-air heater related single equipment commissioning
including its system acceptance.
2) Related to the steam pipes confirmed sweep qualified.
3) Secondary-air heater and its system’s interlock、protection、alarm and other remote
checking.
(13) Soot blower and its system commissioning;
1) To check and confirm soot blower related single equipment commissioning including
its system acceptance.
2) Soot blower steam source pipes confirmed sweep qualified
3) Soot blower and its system’s interlock、protection、start-stop sequence control、 alarm
and other remote control checking.
(14) Pulverized system cold status commissioning;
1) Coal mill lubricating oil system commissioning.
2) Action check test of each shutoff and adjustment valves dampers.
3) Coal mill、coal feeder interlock protection and sequence control check test.
4) Coal mill explosion protection system commissioning.
5) Coal mill、coal feeder static checking and acceptance including related systems.
6) Coal feeder individual system trial running, with C&I go on weighing in calibration of
coal feeder belt.
7) Coal mill individual system trial running, fill in trial running record sheets and
acceptance.
(15) Boiler blowing out;
1) To confirm boiler blowing out programme.
2) To provide boiler blowing out system diagram, and the request of the temporary
system.

SLY-HPE-A-01 R e v . 0 Issue Date 26/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 27/
27/49

3) Check the muffler、collect dirty things equipment、target design and installation


condition.
4) Blowing steam temperature and pressure measurement and control point selection.
5) Checking individual systems that will be into operation for steam blowing out
comprehensively.
6) Checking steam blowing temporary system.
7) To test for the temporary control valves.
8) Budget required for fuel、coal and sweet-water dosage during boiler blowing out.
(16) Coordinate with chemistry for boiler chemical cleaning;
(17) Burner action test;
(18) Check the steam drum inner devices;
(19) Check boiler expansion system;
(20) Individual system trial running and acceptance ;
(21) Compile boiler individual system commissioning reports;
6.1.2 Items of Over-all Start-up Commissioning
(1) To test and confirm C&I signal and alarm system action, steam turbine、electrical、
boiler interlock and protection;
(2) To test and confirm auxiliary equipment emergency stop buttons、interlock and
protection;
(3) To check and confirm system and auxiliary equipment sequence control system
(SCS) ;
(4) To confirm MFT protection static state test;
(5) To check and confirm oil burner sequence control system;
(6) To confirm fuel oil system oil pressure and oil pressure adjustment range;
(7) Coordinate with C&I to test flame detecting system.
(8) Ignition of boiler;
(9) To check steam tightness and record boiler expand parameters.
(10) Coordinate with manufacturer to adjust safety valves.
(11) Coordinate with the steam turbine and electrical professionals to do no-load test;
(12) Pulverizing system hot commissioning;
(13) Boiler combustion adjustment test;
(14) Boiler minimum stability test without oil;
(15) Coal mill change-over test;
(16) Steam temperature adjustment test of boiler;
(17) Coordinate with the chemistry to control steam and water quality;
(18) Coordinate with the C&I to put modulating control system(MCS) in service;

SLY-HPE-A-01 R e v . 0 Issue Date 27/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 28/
28/49

(19) Participate load rejection test;


(20) Island operation test;
(21) Reliability Run
(22) Complete commissioning reporting.

6.2 Turbine
6.2.1 Individual system commissioning item
(1) Checking and confirming the Auxiliary equipment individual system commissioning
conditions, Turbine oil circulation and flushing conditions;
(2) Checkout and confirm alarm status of auxiliary equipments.
(3) Checkout and confirm valves of turbine side.
(4) Coordinate with chemistry for chemical cleaning of turbine.
(5) Auxiliary equipment protections, interlock and sequence control test
(6) Commissioning test of circulating water system
1) DCS(or PLC) operate and control function test and interlock protection putting into
operation.
2) Circulating water pump commissioning and system putting into operation
a) Circulating water pump commissioning and system commissioning adjustment
b) Checking the circulating water pump, system alarm signal and Interlock
protection
c) Circulating water pump off-the-line:
3) Wash-water pump and rotary filter commissioning
a) Rotary filter, wash-water pump commissioning and system commissioning test
b) system washing
4) Finish the commissioning records and commissioning quality inspection
(7) Opened cooling water system commissioning test
1) Checkout the C&I signal and interlock protection
2)Commissioning and adjustment of opened cooling water pump
3) System pipes water washing and valve adjustment
4) Automatic make up water system commissioning test.
5) Coordinate with C&I for program operation test
6) System put into operation and adjusting
(8) Commissioning test of closed cooling water pump system
1) Checkout the C&I signal and interlock protection
2) Commissioning and adjustment of closed cooling water pump
3) System pipes water washing and valve adjustment
4) Automatic make up water system commissioning test
5)Working in the thermal control program operation test

SLY-HPE-A-01 R e v . 0 Issue Date 28/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 29/
29/49

6) System put into operation and adjusting dynamically


(9) Auxiliary steam pipes blow wash
1) Checkout the C&I signal and interlock protection
2) Auxiliary steam system steam purging the piping
3) Auxiliary steam system thermal state checking of safety valve
4) Pressure reducer and attemperator commissioning test
5) System put into operation and dynamic adjustment
(10) Condensate Water System
1) Checkout the C&I signal and protective interlocks
2)Condensate pump commissioning and recalculating system adjustment.
3)Water flush the system pipes and valves adjustment.
4)Condensate make up water system commissioning and system adjustment.
5)Working in Thermal Regulator stored program control running test.
6)System running and adjusting dynamically
(11) Commissioning test of feed water Deaerating System
1)Checkout the C&I signal and protective interlocks
2)Water flush the system.
3)System valves adjustment.
4)Check the deaerater safety valve
6)System running and adjusting dynamically
(12) Commissioning test of electrically driven feed pump.
1) Checkout the C&I signal and protective interlocks
2)Auxiliary oil pump commissioning and lube oil system、working oil system adjustment.
3)Generator drive coupler commissioning.
4)Booster pump commissioning (recalculating by electrically driven feed pump)
5)Commissioning of electrically driven feed pump group (recalculating)
6)Flush the desuperheater water pipes and HP feed water pipes
7)Electrically driven feed pump group on-load commissioning.
(13) Commissioning test of T-BFP
1) Checkout the C&I signal and protective interlocks
2)Small turbine regulation, safety protection system static test and cooperate with C&I
staff to carry out MEH commissioning test.
3)Flush the small steam turbine inlet pipes.
4)Commissioning test of small turbine lubricate system and control oil system
5)Small turbine single running and overspeed test.
6)Commissioning of T-BFP trial operation with recirculation
7)Pump group vibration measurement and surveillance.

SLY-HPE-A-01 R e v . 0 Issue Date 29/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 30/
30/49

(14) Commissioning test of vacuum system


1)Checkout the C&I signal and protective interlocks
2)Eject pump commissioning and system adjusting
3)Flush pipes of system and adjust valves.
4)Vacuum test and check tightness of system.
5)Put vacuum system into operation and Adjust system parameters dynamically.
(15) Steam extraction heater and drain system commissioning test.
1)Checkout the C&I signal and protective interlocks
2)Flush system pipes (steam side 、water side and drain water)
3)Adjustment and commissioning test of LP-heater automatic drain water device
4)Adjustment and commissioning test of Hp-heater automatic drain water device
5)Adjustment and commissioning test of LP-heater critical drain water device
6)Adjustment and commissioning test of Hp-heater critical drain water device
7)Adjustment of extraction check valve control system .
8)System running
(16) Commissioning test of shaft seal steam supply system
1)Checkout the C&I signal and protective interlocks .
2)Flush the shaft seal steam pipes .
3)Flush the system desuperheater water pipes
4)Adjustment of steam supply temperature-decreased pressure reducer
5)Adjustment of shaft seal pressure device.
6)Shaft seal cooler running and shaft cooling fan commissioning test.
7)System commissioning
8)Commissioning test of shaft seal heating device.
(17) Commissioning test of generator inner cooling water system.
1) Checkout the C&I signal and protective interlocks .
2)Commissioning test and adjustment of cooling water pump.
3)Flush the cooling water system pipes and valve adjustment
4)Adjustment of automatic make up cooling water system
5)Commissioning test of water tank inflation system.
6)Commissioning test of Water Treatment device.
7)Water cooling device commissioning test and system running adjustment
(18) Commissioning test of generator sealing oil system
1)Checkout the C&I signal and protective interlocks .
2)Commissioning and system adjusting of seal oil pump.
3)Adjust vacuum degree of seal oil tank.

SLY-HPE-A-01 R e v . 0 Issue Date 30/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 31/
31/49

4)Flush the seal oil pipes .


5)Commissioning test of seal oil device.
6)System running and adjusting dynamically .。
(19) Commissioning test of generator hydrogen cooling system.
1) Checkout the C&I signal and protective interlocks .
2)System blow
3)Leakproofness test of generator hydrogen cooling system.
4)Adjustment and commissioning of system desiccators
5)Commissioning and adjustment of generator hydrogen charging and discharge .
(20) Commissioning test of lube oil system and lube oil purification unit
1)Checkout the C&I signal and protective interlocks .
2)Commissioning and adjustment of the oil transport pump.
3)Commissioning test of Oil purifier
4)System running and adjusting dynamically.
(21) Commissioning test of jacking oil system and turning gear system
1) Checkout the C&I signal and protective interlocks .
2)Commissioning and adjustment of the jacking oil pump .
3)Adjust the jacking oil pressure distribution and shaft neck uplift height.
4)Commission and commissioning of automatic/manual operation turning gear
(22) Commissioning test of steam turbine regulation and safety protection system .
1)Checkout the C&I signal and protective interlocks .
2)Static testing of hydraulic control system
3)Static testing of security system
4)Measure the MV&GV turn-off time
5)Working in DEH static testing.
(23) Commissioning test of bypass system .
1)Checkout the C&I signal and protective interlocks .
2)Flush the bypass pipes and desuperheater water system
3)Commissioning test of control oil pump、static testing of control oil station.
4)Commissioning test of control oil regenerative system
5)Commissioning test of linked system
6)System running and function adjust
(24) Hold on the individual system commissioning acceptance.
(25) Complete the commissioning reports.
6.2.2 Over-all start up commissioning test
(1) Check and affirm each system have the conditions of over-all start up.

SLY-HPE-A-01 R e v . 0 Issue Date 31/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 32/
32/49

(2) Check and affirm interlock and protection of auxiliary systems into operation
(3) DEH combined-commissioning and simulation test.
(4) Test turbine protection system.
(5) Organize the Turbine、Boiler and Generator interlock test.
(6) Generator hydrogen change-over.
(7) Turbine rolling up, warming up, 3000r/min test and no-load test.
(8) Measure the bearing vibration and temperature in Turbine no-load and each operating
conditions.
(9) Cold and hot start-up commissioning test,
(10) Function test of DEH.
(11) Main steam throttle valves and governing valves of turbine tightness tests .
(12) Overspeed test
(13) Hot flush commissioning of heater steam side .
(14) Running test of HP-heater、LP-heater and deaerator.
(15) Checking the Water-feeder turbine on-load conditions.
(16) Coordinating with C&I to process HP、LP by-pass system test.
(17) Unit load test.
(18) Unit island operation test
(19) MV&GV movement test
(20) Generator hydrogen leakage monitoring
(21) Coordinate with the C&I to put modulating control system(MCS) in service;
(22) Reliability Run
(23) Complete commissioning report.

6.3 Electricity
6.3.1 Individual system Commissioning Items
(1) Check the internality and rationality of individual system;
(2) Participate in individual system commissioning, master situation and problem of
individual system commissioning;
(3) Assist constructor with problem handling during individual system commissioning.
(4) Power transformer system commissioning
Commissioning items are as follow:
1)Transformer, HV circuit breaker, disconnecter commissioning and secondary check of
protection and measurement control;
2)Measurement and cooling system commissioning;
3)The whole unit function commissioning;

SLY-HPE-A-01 R e v . 0 Issue Date 32/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 33/
33/49

4)Acceptance.
(5) Generator-transformer unit commissioning
1)Generator, transformer, circuit breaker, disconnecter commissioning, and secondary
circuit commissioning including protection, measurement, control, speed regulation,
command etc.;
2)Transformer’s measurement and cooling system commissioning;
3)The whole unit function test;
4)Protection test among mechanical, boiler, electric and C&I specialities;
5)Acceptance.
(6) Generator excitation system commissioning
Commissioning items are as follow:
1)Manual and automatic excitation system and relative secondary circuit commissioning;
2)The whole unit function test;
3)Acceptance.
(7) Synchronization system commissioning
1)Check synchronizing voltage circuit, frequency and voltage regulating circuits of
synchronization system;
2)Energizing test of synchronization system.
(8) Transmission and distribution system
1)Secondary circuits check of circuit breaker and disconnecter;
2)The whole unit function test;
3)Acceptance.
(9) DC power system commissioning
DC panel, DC power circuit and secondary circuit commissioning and trial run.
(10) Electro Static Precipitator system
1)device and secondary commissioning;
2)No-load voltage rising test;
3)Shaker operating test.
(11) Auxiliary power transfer system commissioning
1)Check secondary circuit;
2)Transfer test.
(12) UPS system commissioning
1)UPS secondary circuit commissioning;
2)Transfer test and trial run.
(13) Essential power system commissioning
1) Essential power circuit commissioning

SLY-HPE-A-01 R e v . 0 Issue Date 33/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 34/
34/49

2) Essential power operation test


(14) Fault Recorder system commissioning
1)Check secondary circuit;
2)Trial run.
(15) Auxiliary system commissioning
1)Check secondary circuit;
2)Operation test;
3)Motor no-load trial run.
Note: Auxiliary system commissioning items don’t include motors which capacity is less
than 50kW. They belong to pre-commissioning scope.
(16) Power plant micro-computer monitoring system commissioning
1)Element check;
2)Secondary circuit commissioning;
3)Network device test;
4)Interval layer interlocking logic test;
5)AVQC function setting and test;
6)UPS system commissioning;
7)GPS system commissioning;
8)Background computer system commissioning;
9)Synchronization system commissioning;
10)Movement function system commissioning.
(17) Voltage step-up system commissioning
1)Static commissioning and acceptance of protection device, monitoring device and
safety automatic device;
2)Secondary circuit check and transmission;
3)Secondary circuit and polarity check of TV and TA;
4)Secondary circuit check and transmission of CB and disconnecter;
5)The whole set transmission and all protection function action check;
(18) Participate in individual system trial run and acceptance;
(19) Edit electric speciality individual system commissioning conclusion.
6.3.2 Unit over-all start-up commissioning items
(1) Generator-transformer unit’s control, signal and protection transmission test;
(2) Measure TV and TA’s secondary load;
(3) Excitation system simulation test;
(4) Synchronization system simulation test;

SLY-HPE-A-01 R e v . 0 Issue Date 34/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 35/
35/49

(5) Auxiliary power fast speed transfer device and system simulation test;
(6) Interlocking test among mechanical, electric and boiler;
(7) Enable relative protection of generator-transformer unit;
(8) At different rotation speed of steam turbine, measuring insulation resistance, AC
impedance and power loss of rotor;
(9) No-load characteristic test of excitation system;
(10) When generator short circuit, check all convertors’ ratio, phase, secondary load,
ammeters’ indication and protection settings, record generator short circuit characteristic
(record exciter load characteristic at the same time);
(11) At generator no-load condition, after raising voltage from zero, check all TVs’
secondary voltage value, phase sequence and instruments’ indication, check protection
action value, record generator-transformer’s no-load characteristic;
(12) Measure generator stator’s residual voltage and phase sequence after
demagnetizing, record generator demagnetizing time constant;
(13) When generator no-load, test excitation automatic regulation device;
(14) Generator synchronization system phase confirmation and grid connection test;
(15) Synchronization simulation test;
(16) After unit connecting to the grid, check protection and measurement circuit, working
channel and standby channel transfer test of excitation automatic regulation device with
load, difference regulation characteristic check and static difference ratio test with load;
(17) Measure shaft voltage at different load;
(18) Measure current circuit’s phase and differential current of differential protection at
different load;
(19) Working and standby HV auxiliary power supply transfer with load;
(20) Check electric monitoring system;
(21) When unit load shedding test, measure and record generator and automatic
excitation regulator relative electrical value’s change, overshoot, surge times and stable
time etc.;
(22) Handle relative defect and abnormal situation, solve all technical problem occurs
during trial run period;
(23) Reliability Run
(24) Complete commissioning report.

6.4 C&I
6.4.1 Individual system commissioning
1) Check the principle diagram 、 wiring diagram and configuration diagram. Bring

SLY-HPE-A-01 R e v . 0 Issue Date 35/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 36/
36/49

modification suggestion forward


2) Take part in the commissioning、training and approval work of large and important
devices before leave the factory
3) Coordinates with ESSAR Construction to inspect the measuring instruments, the
sampling unit to install the situation and calibration tail, test the leakproofness of the pipe
of instruments, and record it. Repeat the work if necessary.
4) coordinates with ESSAR Construction to inspect the implementing agency and the base
adjusting device installs situation
5) coordinates with ESSAR Construction to check out the regulation of primitive instruments
and special gauges
6) coordinates with ESSAR Construction to check out the reliability of control system
7) coordinates with Manufacturer to do the power on work and software restore work about
DCS
8) checkout computer hardware and checkout the definition of I/O channel
9) checkout the configuration of DCS and change parameters
10) computer monitor system commissioning and in service
11) coordinates with electrical speciality to check out the measuring circuit
12) coordinates with electrical speciality to test interlock and protection
13) coordinates with ESSAR Construction to do the signals channel correction test and
remote operation test, what includes C&I instrument , chemical analyse instruments, C&I
signals, temperature transmitter, pressure transmitter, temperature switch, pressure
switch, and the correction of signals circuit of DCS and protection system
14) Coordinates with ESSAR Construction to test the remote operation of actuator
15) Take part in checking adjustment, do the characteristic test.
16) Coordinates with chemical speciality to cleaning up the boiler
17) SCS regulation and simulation test
18) FSSS regulation and simulation test
19) open cycle test of MCS and static setting
20) SOE regulation and in service
21) Related auxiliary interlock and protection commissioning work and test
22) Bypass control system regulation and open cycle test
Main protection system of steam turbine regulation and static test
23) Steam monitor system regulation and in service
24) DEH regulation and simulation testing
25) Monitor system and protection system of Boiler feed water pump regulation and in
service

SLY-HPE-A-01 R e v . 0 Issue Date 36/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 37/
37/49

26) DEH of Boiler feed water pump regulation


27) Testing with safe system
28) testing with main oil system
29) check the technical norms of DCS
30) coordinates with ST speciality to driving turbine rolling-up test.
31) coordinates with ST speciality to do over-speed test
32) Function commissioning for mechanical, boiler and electric interlocking
33) Quality acceptance form of C&I individual system commissioning and trial run
34) write regulation conclusive of C&I individual system commissioning
6.4.2 Over-all Start-up Commissioning
1) Cooperate with turbine and boiler specialty check and confirm interlock and protection
input of auxiliary engines
2) Function testing for mechanical, boiler and electric interlocking
3) According to the unit operation,input every control devices,and input analog control
system
4) Input main protection of electricity、 boiler、 turbine
5)Input bypass control system,and formulate the dynamic parameters
6)Input turbine electro-hydraulic control system,realize various functions
7)Cooperate turbine specialty with doing impulse starting
8)Cooperate turbine specialty with doing tests else
9)Cooperate with electricity speciality doing test
10) Cooperate with first synchronize
11) Cooperate turbine specialty with doing over-speed test
12) Cooperate with boiler specialty doing leak test,and formulate safety door
13) Gradually input boiler side all automatic adjusting devices
14) Gradually input steam turbine side all automatic adjusting devices
15) After all individual systems of analog control system in service,inspect quality,formulate
the dynamic parameters,according to the operation condition,doing disturbing test,improve
the adjusting quality
16) Cooperate every test of on-load unit section
17) Cooperate boiler specialty with powder process in service
18) Cooperate boiler specialty with doing burning adjustment test
19) Cooperate ST specialty with doing auxiliary engine change test
20) All individual systems of analog control system operating normal, the unit operation
condition is stable, input coordination control system
21) Coordinated control system load change test

SLY-HPE-A-01 R e v . 0 Issue Date 37/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 38/
38/49

22) To help the operation personnel technical exchanges,guide operation


23) Attend accident analysis,assist in formulating measures
24) Reliability Run
26) Complete the commissioning reports

6.5 Chemistry
6.5.1 Individual system Commissioning Item
(1) Every minitype test, Include leechdom purity 、 concentration judge 、 coagulant
concentration and add quantity test, circulating water treatment medicament selection,
chemical cleaning small test
(2) Condensate polishing system commissioning
1) Recycling Equipment Systems Inspection
2) Water washing
3) Resin loading
4) Resin inspection, treatment and recycling
(3) Boiler chemical cleaning
1) Compiling boiler chemical cleaning project
2) Boiler chemical cleaning system diagram drawing
3) To inspect and guide the implementation of chemical cleaning
4) Checking and judging of chemical cleaning effect
(4) Turbine chemical washing.
1)Write a scheme of turbine chemical washing.
2)Make a turbine chemical washing drawing
3)Checking and guidance of turbine chemical washing.
4)Turbine chemical washing effect and checking qualification
(5) Steam&water dosing system and steam&water sampling frame equipment
commissioning test.
1)Check the single commissioning test .
2)Measure point checking、valve actuation test.
3)System linkage and stored program control protection test.
4)System washing.
5)Adjust the sampling frame cooling equipment
6)Check the analyzers and put into the system.
(6) Individual system commissioning chemical supervision.
1)Condenser, deaerator washing and water quality supervision.
2)Boiler water filling and cold state wash water quality supervision.

SLY-HPE-A-01 R e v . 0 Issue Date 38/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 39/
39/49

3)Boiler lighting up、hot wash in boosting time and thermodynamic system steam&water
supervision.
4)Supervise steam water quality during blowing out.
(7) Assist the construction unit deal with the problems in commissioning, present projects or
advises to solve the problems in individual system commissioning test.
(8) Hold on the acceptance after individual system commissioning test.
(9) Complete the individual system commissioning reports.
6.5.2 Over-all start-up commissioning item
(1) The sampling and dosing system is put into operation;
(2) Coordinating with the C&I workers to check meters、bringing into service the sequence
control equipment;
(3) Adjustment capability and output water quality of chemical water treatment equipment
make sure they can reach design requirement;
(4) Supervising boiler water and steam quality;
(5) Supervising boiler chean silicium after parallel in with load;
(6) Condensate water、drain recovery processing supervise;
(7) Supervising deoxygenization effect of deaerator;
(8) Supervising quality of generator cooling water and hydrogen;
(9) Thermal system anti-corrosion monitoring during the unit is outage;
(10) Reliability Run
(11) Complete commissioning reports;

7. Acceptance and Signature of Individual System Commissioning

7.1 commissioning of the individual systems for the HPE equipments, organized
implemented and accepted signature by HEPE.
7.2 ESSAR operators will carry out operations of individual system commissioning and be
guided by HEPE.
7.3 ESSAR Construction will eliminate defects.
7.4 HPE organize manufacturers’ representatives to participate in the commissioning and
acceptance.
7.5 After individual system commissioning is completed, HEPE is responsible for the review
the acceptance datas of commissioning, and to confirm the conditions of over-all start-up.

8. Acceptance and Signature of Over-all Start-up Commissioning


8.1 Three-level Acceptance is: the ESSAR Power, HPE and HEPE chief engineer, HPE and

SLY-HPE-A-01 R e v . 0 Issue Date 39/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 40/
40/49

HEPE commissioning engineer.


8.2 The owner acceptance of the project as stipulated in the contract, or mutually agreed
upon project commissioning and acceptance, in principle, could include the following:
Super heater, reheater, steam drum safety valve setting;
Boiler leak test;
Boiler Combustion and B-MCR, T-MCR, the minimum load of stable combustion, cold
and hot start tests and other conditions;
Turbine vacuum leak test, speed test, the island running test;
Electric no-load test, auxiliary power switch test;
Load test, 14 days reliability run, protection and thermal control system is put in rate
statistics.
8.3 HPE and HEPE chief engineers accept the project work
See the additional acceptance and signature documents.
8.4 HPE and HEPE commissioning engineer accept the Project
See the additional acceptance and signature documents.
8.5 the contents of the acceptance signature of commissioning projects:
1. Review and approval of commissioning programs and security measures;
2. To participate in the commissioning process;
3. Review the commissioning record and sign;
4. Confirm the conclusions of the commissioning assessment and commissioning reports;
5. Rectification or eliminating defects proposed recommendations;
6. Complete acceptance of the signature process ESSAR Power.

9. Principles of Quality Assurance


9.1 All items of commissioning should be completed;
9.2 All commissioning items should be executed with Three Acceptance;
9.3 Respect for the ESSAR Power’ right to participate and supervise of the whole process of
commissioning;

10 . Process of Over-all Start-up


10.1 Organize to learn the programs, procedures of commissioning;

SLY-HPE-A-01 R e v . 0 Issue Date 40/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 41/
41/49

10.2 CH organizes HPE, ESSAR Power, ESSAR Construction, HEPE, installation


supervisors, manufacturers representatives and other groups to inspect and accept
prerequisites of Over-all Start-up Commissioning.
10.3 CH compiled the project start planning to submit ACC for approval;
10.4 ACC will discuss and confirm conditions of Over-all Start-up of unit.
10.5 Execute Over-all Start-up commissioning procedures of boiler, turbine, electrical, C&I
and chemical
10.6 Complete the relevant signature of each phase during start-up commissioning ;
10.7 After Start-up Commissioning, CH fills in and sign the corresponding documents;
10.8 HPE will turn unit over to ESSAR Power after PAC certificate signed.
10.9 Compile Commissioning Report of Over-all Start-up commissioning.
Note:
a) Over-all Start-up commissioning procedures are prepared by the HEPE, Approved by
the ACC.
b) Compile the detailed plan of Over-all Start-up . Perform commissioning work of items
according to the plan.
c) Sign after finishing items of Over-all Start-up Commissioning
In order to complete items of Over-all Start-up Commissioning with high quality, it should
be signed and identified by corresponding teams after finishing the each commissioning
item.

11. Prerequisites for Over-all Start-up

11.1 :
Field and infrastructure conditions:
11.1.1 The construction site has been isolated reliably from related systems or applicable
isolation measures have been used.
11.1.2 Scaffold and obstacle that might block the Trial Running or cause firing has been
removed. The work site is cleared up with all covers of channel, stairs and balustrade
completed.
11.1.3 Sufficient lighting including emergency lighting devices is available at site.
11.1.4 Fire fighting and smooth communication are available.
11.1.5 Water supplying and draining system is available and can meet the requirements.
11.1.6 All the infrastructure and installation works related to the unit has been completed in
accordance with the design requirements.

SLY-HPE-A-01 R e v . 0 Issue Date 41/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 42/
42/49

11.1.7 Tagging of equipment, piping and valves has been verified. Flow indication is correct.
Latest system flow-sheet is available at site.
11.1.8 The start-up procedure and technical measures have been approved and detailed
instruction has been forwarded to all personnel attending Trial Running.
11.1.9 Required diagrams, recording sheet, safety protection tools, and operational tools &
measuring devices are ready for service.

11.2 Prerequisites for boiler and auxiliary equipment start-up:
11.2.1 Corresponding equipments or systems has been test operated successfully with
main tests completed;
11.2.2 logics combined with protection, signals and modulating devices finished
commissioning and are ready for service after acceptance.
11.2.3 ID fan, FD fan, PA fan, and SA fan, Air-Preheater associated with control dampers,
isolating dampers, and relative logics are ready for service after commissioning.
11.2.4 Boiler water/steam system and drainage system are ready for service,Steam &
water system, drainage system, boiler water circulating pump system
commissioning is finished;
11.2.5 Installation for boiler soot-blowing system is completed and static commissioning has
been finished;
11.2.6 Flame detection video system and flue gas temperature probe commissioning has
finished.
11.2.7 Local drum level indicator (dual-color type) and electrical contact level indicator are
ready for service.
11.2.8 The diesel oil system associated with the pneumatic control valve, the motor
operated valve and isolating valves are ready for service.
11.2.9 Maintenance holes, explosion resistant doors and fire watching windows are intact
and functional.
11.2.10 Boiler water/steam sampling system and chemical injection system are available.
11.2.11 Auxiliary steam system is available and relief valves have been calibrated.
11.2.12 Combustion air and flue gas system are ready for service.
11.2.13 Desuperheat water system is ready for service.
11.2.14 Cold ventilation test is completed.
11.2.15 Chemical cleaning to boiler has been completed.
11.2.16 Steam blowing is completed.
11.2.17 Logic tests including MFT tests are checked.
11.2.18 Temperature indication of boiler tube wall and thermal expansion indicator are
11.2.19 available.

SLY-HPE-A-01 R e v . 0 Issue Date 42/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 43/
43/49

11.2.20 Instruments within combustion air system, flue gas system, water & steam system,
11.2.21 Diesel oil system and coal conveying system are checked and are ready for service.
11.2.22 Fire extinguisher or fire fighting system is ready for service.
11.2.23 Air compressor system for both instrument and plant uses is in service.
11.3 Prerequisites for turbine and auxiliary equipment start-up:
11.3.1 Commissioning of single equipment and individual system operation in turbine plant
is completed, verified and accepted.
11.3.2 Commissioning of C&I regulating equipment, interlock and protection, alarm signal
and monitor system have been finished.
11.3.3 EH oil system and lubricating oil system cleaning and circulating is completed with
the oil quality meeting requirements.
11.3.4 Commissioning of EH oil system, lubricating oil system and jacking oil system is
completed.
11.3.5 Adjustment of operating mechanism of regulating system is completed.
11.3.6 Chemical cleaning, flush, blowing out of steam and water system have been finished.
11.3.7 Trial Running of steam-driven feed water pump and other auxiliary equipment have
been finished.
11.3.8 Installation and individual system commissioning of auxiliary steam, gland sealing
system, condensate water system, circulated cooling water system, vacuum system,
cooling water system, deaerator, HP and LP heater and drain water system have
been finished, and all equipments are ready for service.
11.3.9 Generator inner cooling water and hydrogen cooling system commissioning has
been finished, and is ready for service.
11.3.10 Vacuum system commissioning has finished, and are ready for service.
11.3.11 Jacking oil system and turning gear equipment commissioning have been finished,
as well as C&I parts.
11.3.12 Dosing system for condensate water system and feed water system is available.
11.3.13 Uninterrupted power supply transfer test has been finished, and put in standby
status.
11.3.14 Required special tools and monitoring instruments for unit start are available.
11.4 Prerequisites for C&I system for unit start-up
11.4.1 DCS system run in normal condition(FSSS、SCS、DAS、and CCS).
11.4.2 The test of DEH system have been completed.
11.4.3 Commissioning of OIS and BTG is completed with enough reliability. The
commissioning of transmitters, solenoid valve, temperature &pressure switches, position
switches, hydraulic and pneumatic have been completed;.

SLY-HPE-A-01 R e v . 0 Issue Date 43/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 44/
44/49

11.4.4 Commissioning of ignition sequence control system have been completed, and
ready for service.
11.4.5 Commissioning of bypass control system have been completed, and ready
for service.
11.4.6 Commissioning of turbine lubricant and auxiliary systems has been completed,
and ready for service.
11.4.7 Interlock test of condensate water and LP heater system have been completed, and
ready for service.
11.4.8 Commissioning of SOE, history record, tabular print, operator record and alarms
have been completed, and ready for service.
11.4.9 Oxygen measuring loop has tested and ready for service.
11.4.10 The boiler and turbine interlock have been successfully tested and ready for service.
11.4.11 TSI and other protection system have been commissioned.
11.4.12 Boiler Main Fuel Trip (MFT) has been successfully commissioned.
11.4.13 Single equipments system commissioning has verified to meet the accepted
requirement.
11.4.14 Other C&I systems are ready for service.
11.5 Prerequisites for electrical system start-up:
11.5.1 The arrangement of generator terminals bus is correct.
11.5.2 The connection and polarity of generator CT and PT are correct.
11.5.3 The static commissioning test of generator-transformer protection system have been
completed, and the protection system can be fully put in service.
11.5.4 The insulation of generator stator and rotor meet the requirements.
11.5.5 Generator field circuit breaker and switch can be operated reliably.
11.5.6 The check and commissioning of synchronizing system have been completed.
11.5.7 The polarity of excitation circuit is correct.
11.5.8 The commissioning tests of excitation system have been completed before excitation
system start-up, the protection of excitation system can be put in service.
11.5.9 Transfer test of standby power supply has been completed and satisfy the
requirements.
11.5.10 The high-voltage static test of generator, the commissioning tests of excitation
transformer has been completed.
11.5.11 The high-voltage tests of generator field circuit breaker, main transformer and unit
service transformer have been completed.
11.6 Prerequisites for chemical systems:

SLY-HPE-A-01 R e v . 0 Issue Date 44/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 45/
45/49

The chemical dosing systems and sampling system can be put into operation, the
chemicals have been prepared sufficiently.
Enough qualified demineralised water has been produced and stored in the
demineralised water tanks.
The chemical make-up water treatment system can be put into operation normally and
stably.

12. Unit Start-up Procedure

The unit start-up period means the period from the first ignition of the boiler to Reliability Run.
The Unit Start-up must be approved by the Commissioning Committee. The Unit Start-up is
divided into three phases: no-load operation, loaded operation and full load operation.
12.1 No- load operation Procedure:
12.1.1 Place the related auxiliary equipment and sub-systems into service in accordance
with corresponding procedure.
12.1.2 Start the turning gear after operating parameters meet requirements.
12.1.3Start boiler ignition followed by pressure increasing.
12.1.4Place gland seal into service and start vacuum extraction.
12.1.5 Rolling up turbine the in accordance with the cold start-up curve.
12.1.6 Monitor the shaft vibration and bearing temperature. Fix the vibration problem if
abnormal vibration developed.
12.1.7 Obtain related technical data at unit start-up, speed-up and rated speed.
12.1.8 Tuning test of turbine protection and control system.
12.1.9 Complete electrical tests of generator before synchronization.
12.1.10 Operate the unit under 10-20% of rated load for 2 hours.
12.1.11 Disconnect the generator from the electrical grid and complete seal test of main
steam throttle valves and governing valves.
12.1.12 Complete over-speed test and required adjustments.
12.1.13 Resynchronize the generator.
12.1.14 Place the available auto-control systems into service gradually, and do required
tuning test:
12.1.15 Shutdown the turbine if necessary.
12.2 Loaded operation Procedure:
12.2.1 Pick up load up to 10-15% of rated load.

SLY-HPE-A-01 R e v . 0 Issue Date 45/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 46/
46/49

12.2.2 Place the available auto-control systems into service step by step, and do necessary
tuning test.
12.2.3 Supervise and control water and steam quality within limits.
12.2.4 Place the LP heaters into service and adjust the water level.
12.2.5 Complete initial combustion adjustment.
12.2.6 Place HP heaters into service one by one and adjust water level.
12.2.7 Sampling and control water quality within limits.
12.2.8 Record the unit operating parameters under 25% of rated load, and complete related
turbine check.
12.2.9 Increase unit load to 50% of rated.
12.2.10 Complete the combustion adjustment under this load level.
12.2.11 Place the auto-control system into service and complete precise tuning.
12.2.12 Control the water and steam quality in normal range via adjustments.
12.2.13Record the operating parameters under 50% load and complete related check.
12.2.14Increase load to 75% of rated.
12.2.15 Complete combustion adjustment.
12.2.16Place auto control system into service and complete tuning.
12.2.17 Sample water and steam for analysis and control in normal range.
12.2.18 Record the operating parameters under 75% load and complete related checks.
12.2.19Load increasing to 80% above, complete governor valve test and vacuum test.
12.2.20 Place ESP into service when necessary.
12.2.21Prepare soot blowers for service.
12.2.22 Increase unit load to 100% gradually.
12.2.23 Complete boiler combustion adjustment.
12.2.24Sample water and steam for analysis and control in normal range.
12.2.25Place remains of auto control system into service and complete tuning.
12.2.26Record the unit operating parameters under full load.
12.2.27 Complete CCS tuning.
12.2.28 Complete island test of unit in accordance with applicable procedure.
12.3 Full- load operation Procedure (Reliability test):
12.3.1Unit auto regulation, instrument and protection puted into normally, all the problems
which influence unit running with rated load have eliminated, unit protection have puted into
100%.
12.3.2 Check all the systems and equipments having rated load running conditions according
as operating regulation.
12.3.3 Electrical load meets rated value with operating parameters in normal range.

SLY-HPE-A-01 R e v . 0 Issue Date 46/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 47/
47/49

12.3.4 Water steam quality maintained within normal range.


12.3.5 Boiler is running firing main fuel only with HP heaters, ESP and CCS system in
service, and water steam quality maintained within normal range.
12.3.6 Unit enter reliability test and operating continuously.

SLY-HPE-A-01 R e v . 0 Issue Date 47/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 48/
48/49

13. Commissioning Procedure List

NO. Procedure Documentation Prepared by Note


NO.
Boiler
1 Commissioning Procedure for Boiler Unit Start-up
2 Commissioning Procedure for Steam Blowout
3 Commissioning Procedure for Boiler Safety Valve
System
4 Commissioning Procedure for Fuel Oil System
5 Commissioning Procedure for Combustion Air &
Flue Gas System
6 Commissioning Procedure for Flue Gas System
7 Commissioning Procedure for Coal Pulverized
Handling System
Turbine
1 Commissioning Procedure for Turbine Unit
Start-up
2 Commissioning Procedure for Circulating Water
System
3 Commissioning Procedure for Condensate Water
System
4 Commissioning Procedure for Motor-driven
Feed-Water Pump & Steam-Driven Pump
5 Commissioning Procedure for Generator
Hydrogen Cooling System
6 Commissioning Procedure for Bypass System
7 Commissioning Procedure for Turbine Governing
and Protection system
8 Commissioning Procedure for Load Rejection
Test
9 Commissioning Procedure for Condenser and Air
Extraction System
10 Commissioning Procedure for Feed Water &
Deaerator
11 Commissioning Procedure for Turbine Auxiliary
Steam System Blowout
Electrical

SLY-HPE-A-01 R e v . 0 Issue Date 48/49



Department: Commissioning Program of Page:
Commissioning India Mahan 2x600MW Coal-fired Project 49/
49/49

1 Commissioning Procedure for Generator Start-up

2 Commissioning Procedure for Synchronizing Test

3 Commissioning Procedure for AVR Dynamic Test


4 Commissioning Procedure for Short & Open
Circuit Test
5 Commissioning Procedure for Excitation
Regulation
C&I
1 Commissioning Procedure for Control System
Energizing and Software Recovering
2 Commissioning Procedure for Furnace Safeguard
Supervisory System (BMS)
3 Commissioning Procedure for Turbine
Supervisory Indication(TSI) System
4 Commissioning Procedure for Sequence Control
System (SCS)
5 Commissioning Procedure for Turbine
Electro-Hydraulic (DEH) Control System
6 Commissioning Procedure for Turbine Emergency
Trip System (ETS)
7 Commissioning Procedure for Modulating Control
System (MCS)
8 Commissioning Procedure for Turbine
Electric-Hydraulic Control System (DEH)
Chemistry
1 Commissioning Procedure for Chemical Dosing
System
2 Commissioning Procedure for Sampling System
3 Commissioning Procedure for Water & Steam
Quality Supervision and Control

SLY-HPE-A-01 R e v . 0 Issue Date 49/49

You might also like