Professional Documents
Culture Documents
Commissioning Program
For
Mahan 2×600MW TPP
Content
1. PROJECT DESCRIPTION ............................................................................................................................................ 3
1.1 GENERAL..................................................................................................................................................................... 3
1.2 TECHNICAL SPECIFICATION ........................................................................................................................................ 3
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.
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
3. Commissioning Organization
Commissioning
Director (CD)
Deputy CD.
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.
(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.
(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.
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;
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
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
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
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
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
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.
5.4 HEPE should attend pre-commissioning inspection in major HPE equipment and
systems.
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.
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
(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;
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
(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
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.
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;
7.1 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.
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.
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.
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;.
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:
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.
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.
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.